Copyright ©

TO READER
This manual has been printed for a kilful engineer CNH France S.A.
to supply necessary technical information to carry Rue des Meuniers - 60330
out service operations on this machine. Le Plessis Belleville - France

Read carefully this manual to collect correct infor-

mation relevant to repair procedures.

For any question or remark, or in case of any error

relevant the contents of this manual, please con-
tact:

REFERENCE
Beyond this Service Manual, also refer to
documents hereunder listed:

Z Operator’s Manual
Z Parts Catalogue

COMPLETE HANDBOOK FOR INSTRUCTIONS
AND REPAIRS
The complete Service Manual consists of two
volumes:
Z 580 Super R - 590 Super R - 695 Super R
Service Manual “LOADER BACKHOE”
Z 580 Super R - 590 Super R - 695 Super R
Service Manual “Engine”
The Service Manuals for “Loader backhoe” and
“Engine” contain the necessary technical informa-
tion to carry out service and repair on machine and
on engine, necessary tools to carry out those op-
erations and information on service standard, on
procedures for connection, disconnection, disas-
sembly and assembly of parts.
The complete Service Manual which covers the
loader backhoe models 580 Super R - 590 Super
R - 695 Super R consists of the following volumes,
which can be identified through their print no. as
stated below:

VOLUME MACHINE TYPE PRINT NUMBER

Service Manual - “Loader backhoe” 580 Super R - 590 Super R - 695 Super R 87570830A
Service Manual - “Engine” 580 Super R - 590 Super R - 695 Super R 9-88900
 Copyright ©

AVOID ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.

A careful operator and / or technician is the best insurance against accidents. The complete ob-
servance of one simple rule would prevent many thousands of serious injuries each year.

This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

SWARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-
ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.

CNH France S.A.

Rue des Meuniers - 60330
Le Plessis Belleville - France

All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
 Copyright ©

LOADER BACKHOE MODELS

The complete range of Loader Backhoe models described in this manual are identified below:

580 Super R 590 Super R 695 Super R

Powershift O O O

Powershuttle O O /
Stabilizer sideshift O O O

Stabilizer centre pivot / / O

Cab O O O

Rops O / /
2WD O / /
4WD O O O

4WS / / O

Pilot control O O O

Mechanical control O O O

Engine Iveco 71 kW - 95 HP model F4GE0454C*D660 O / /

Engine Iveco 82 kW - 110 HP model F4GE0484C*D660 / O /
Engine Iveco 82 kW - 110 HP (4WS) model
/ / O
F4GE0484C*D655
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4
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INDEX
SECTION 00 - SAFETY PRECAUTIONS

SECTION 01 - MAINTENANCE

SECTION 02 - TECHNICAL SPECIFICATIONS

1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 9
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 12
6. LIFTING CAPACITIES................................................................................................................................ 15
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 18
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 19

SECTION 17 - TORQUE CONVERTERS

1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.1 DESCRIPTION AND OPERATION........................................................................................................ 7
2.2 TECHNICAL SPECIFICATIONS............................................................................................................ 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12

SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING................................................................................................................................ 90
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1.13 SPECIAL TOOLS............................................................................................................................... 93

2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION ........................................................................ 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING .............................................................................................................................. 265
2.15 FAULT FINDING .............................................................................................................................. 267

SECTION 25 - FRONT AXLES

1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.3 FAULT FINDING .................................................................................................................................. 23
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 25
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 25
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 80
3.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 84
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140

SECTION 27 - REAR AXLE

1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING .................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING .................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84

SECTION 33 - BRAKES SYSTEM

1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT............................................................................................................... 7
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3. BRAKE CYLINDERS .................................................................................................................................... 8

4. OIL BRAKE TANK ...................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13

SECTION 35 - HYDRAULIC SYSTEM

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 3
1.2 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT PILOT MODELS ...................................................... 5
1.3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .............................................................. 8
1.4 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT MECHANICAL MODELS ....................................... 11
1.5 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS............................................... 13
1.6 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT PILOT MODELS .................................................... 15
1.7 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODEL .............................................................. 18
2. HYDRAULIC PUMP.................................................................................................................................... 21
2.1 DESCRIPTION AND OPERATION...................................................................................................... 21
2.2 TECHNICAL SPECIFICATIONS.......................................................................................................... 22
2.3 LOAD SENSING VALVE ..................................................................................................................... 24
2.4 REMOVAL ........................................................................................................................................... 26
2.5 COMPONENTS ................................................................................................................................... 27
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 28
3. CONTROL VALVES ................................................................................................................................... 32
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 32
3.2 CONTROL VALVES “REXROTH” (PILOT MODELS) ......................................................................... 48
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 71
4.1 DESCRIPTION AND OPERATION...................................................................................................... 71
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 72
4.3 PRECISION SWING CONTROL ......................................................................................................... 74
5. HYDRAULIC CYLINDERS.......................................................................................................................... 77
5.1 LOADER CYLINDER ........................................................................................................................... 78
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 83
5.3 4X1 BUCKET CYLINDER.................................................................................................................... 87
5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 90
5.5 BACKHOE DIPPER CYLINDER.......................................................................................................... 94
5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 98
5.7 SHORT AND LONG TELESCOPIC CYLINDER................................................................................ 102
5.8 STABILIZER CYLINDER (CENTRE PIVOT - 4WS) .......................................................................... 106
5.9 STABILIZER CYLINDER (SIDESHIFT) ............................................................................................. 110
5.10 SWING CYLINDER.......................................................................................................................... 114
5.11 BACKHOE SIDESHIFT LOCKING CYLINDER (SIDESHIFT) ......................................................... 118
5.12 SPECIAL TOOLS............................................................................................................................. 120
6. HYDRAULIC CONTROL LEVERS ........................................................................................................... 121
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 121
6.2 DESCRIPTION AND OPERATION.................................................................................................... 122
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 125
6.4 HYDRAULIC CONTROL LEVER VALVE .......................................................................................... 128
7. FAULT FINDING AND FLOW TESTING .................................................................................................. 131
7.1 PRELIMINARY CHECKS................................................................................................................... 131
7.2 FAULT FINDING................................................................................................................................ 132
7.3 PRESSURE TESTING....................................................................................................................... 136
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SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS............................................................................................... 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 8
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS........................................................................... 9
2.5 TIGHTENING TORQUES .................................................................................................................... 11

SECTION 41 - STEERING SYSTEM

1. STEERING SYSTEM 2WS ........................................................................................................................... 4
2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. POWER STEERING ................................................................................................................................... 12
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 16
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33

SECTION 50 - CAB HEATING AND AIR CONDITIONING

1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM ................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL............................................................................................................... 47
3.9 COMPRESSOR ................................................................................................................................... 51
3.10 SPECIAL TOOLS............................................................................................................................... 65

SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING .................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 25
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 45
2.4 ELECTRICAL DIAGRAMS - ROPS ..................................................................................................... 65
3. CONTROLS AND INSTRUMENTS............................................................................................................. 81
3.1 FRONT INSTRUMENT PANEL (580 Super R - 590 Super R) ............................................................ 81
3.2 FRONT INSTRUMENT PANEL (695 Super R).................................................................................... 83
3.3 SIDE INSTRUMENT PANEL ............................................................................................................... 85
3.4 DIAGNOSTIC SIGNALING .................................................................................................................. 88
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3.5 CALIBRATION OF SPEEDOMETER .................................................................................................. 90

3.6 IMMOBILISER CIRCUIT...................................................................................................................... 91
4. STARTING SYSTEM .................................................................................................................................. 92
4.1 DESCRIPTION AND OPERATION...................................................................................................... 92
4.2 FAULT FINDING.................................................................................................................................. 93
4.3 STARTER MOTOR.............................................................................................................................. 96
5. ALTERNATOR.......................................................................................................................................... 102
5.1 TECHNICAL SPECIFICATIONS........................................................................................................ 102
5.2 DESCRIPTION AND OPERATION.................................................................................................... 102
5.3 COMPONENTS ................................................................................................................................. 104
5.4 REMOVAL ......................................................................................................................................... 105
5.5 PRELIMINARY CHECK AND TESTS................................................................................................ 106
5.6 FAULT FINDING................................................................................................................................ 115
6. BATTERY ................................................................................................................................................. 116
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 116
6.2 DESCRIPTION AND OPERATION.................................................................................................... 116
6.3 BATTERY REPLACEMENT .............................................................................................................. 117
6.4 MAINTENANCE................................................................................................................................. 119
6.5 TESTS ............................................................................................................................................... 121
6.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 123
6.7 BATTERY MASTER SWITCH ........................................................................................................... 123
7. COMPONENT TESTING .......................................................................................................................... 124
7.1 GENERAL INTRODUCTION ............................................................................................................. 124
7.2 COMPONENT TESTING ................................................................................................................... 125
7.3 GROUND POINTS............................................................................................................................. 125

SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 9
5. LOADER ARM REMOVAL.......................................................................................................................... 11

SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION .............................................................. 6
3. BACKHOE ATTACHMENT PILOT CONTROL VERSION.......................................................................... 13
4. REMOVAL AND INSTALLATION ............................................................................................................... 15
5. TELESCOPIC DIPPER REVISION............................................................................................................. 25
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SECTIONS INDEX
Where disassembly of a specific component is required refer to the relevant repair manual section.

SECTION 17: TORQUE CONVERTER

SECTION 21: TRANSMISSION
SECTION 25: FRONT AXLE
SECTION 27: REAR AXLE
SECTION 33: BRAKE SYSTEM
SECTION 35: HYDRAULIC SYSTEM
SECTION 39: CHASSIS
SECTION 41: STEERING SYSTEM
SECTION 50: CAB HEATING AND AIR CONDITIONING
SECTION 55: ELECTRICAL SYSTEM
SECTION 82: LOADER
SECTION 84: BACKHOE
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580 Super R
590 Super R
695 Super R

SECTION 00 - SAFETY PRECAUTIONS

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2 SECTION 00 - SAFETY PRECAUTIONS

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SECTION 00 - SAFETY PRECAUTIONS 3

This warning symbol points out important messages

involving personal safety.
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential haz-
ards and safeguard your safety and personal integ-
rity.
In this manual you will find this symbol together with
the following key-words:
WARNING - it gives warning about improper repair
operations and deriving potential consequences af-
fecting the service technician’s personal safety.
DANGER - it gives specific warning about potential
dangers for personal safety of the operator or other
persons directly or indirectly involved.

TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in the work site or on the road, are caused by the failure of
some individual to follow simple and fundamental safety rules or precautions.

For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the nec-
essary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be conditions that
cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient oper-
ation.

A careful operator or technician is the best precaution against accidents. The complete observance of one sim-
ple rule would prevent many thousands of serious injuries each year.

This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

4 SECTION 00 - SAFETY PRECAUTIONS
SAFETY RULES
Z Carefully follow specified repair and maintenance
procedures.
Z Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts.
We advise to use approved safety clothing such as
anti-slipping footwear, gloves, safety goggles, hel-
mets, etc.
Z Never carry out any repair on the machine if some-
one is sitting on the operator’s seat, except if they
are certified operators to assist in the operation to
be carried out.
Z Never operate the machine or use attachments
from a place other than sitting at the operator’s
seat.
Z Never carry out any operation on the machine
when the engine is running, except when specifi-
cally indicated.
Z Stop the engine and ensure that all pressure is re-
lieved from hydraulic circuits before removing
caps, covers, valves, etc.
Z All repair and maintenance operations should be
carried out with the greatest care and attention.
Z Service stairs and platforms used in a workshop or
in the field should be built in compliance with the
safety rules in force.
Z Disconnect the batteries and label all controls to
warn that the Machine is being serviced. Block the
machine and all equipment which should be
raised.
Z Never check or fill fuel tanks and accumulator bat-
teries, nor use starting liquid if you are smoking or
near open flames as such fluids are flammable.
Z Brakes are inoperative when they are manually re-
leased for maintenance purposes. In such cases,
the machine should be kept constantly under con-
trol using blocks or similar devices.
Z The fuel filling gun should remain always in contact
with the filler neck.
Maintain this contact until the fuel stops flowing
into the tank to avoid possible sparks due to static
electricity buildup.
Z Use exclusively specified towing points for towing
the machine. Connect parts carefully.
Ensure that foreseen pins and/or locks are steadily
fixed before applying traction.
Do not stop near towing bars, cables or chains
working under load.
Z To transfer a failed machine, use a trailer or a low
loading platform trolley if available.
Z To load and unload the machine from the transpor-
tation mean, select a flat area providing a firm sup-
port to the trailer or truck wheels. Firmly tie the
machine to the truck or trailer platform and block
wheels as required by the forwarder.
Copyright ©
Z For electrical heaters, battery-chargers and similar
equipment use exclusive auxiliary power supplies
with a efficient ground to avoid electrical shock
hazard.
Z Always use lifting equipment and similar of appro-
priate capacity to lift or move heavy components.
Z Pay special attention to bystanders.
Z Never pour gasoline or diesel oil into open, wide
and low containers.
Z Never use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non-flammable
non-toxic proprietary solvents.
Z Wear protection goggles with side guards when
cleaning parts using compressed air.
Z Do not exceed a pressure of 2.1 bar, in accordance
with local regulations.
Z Do not run the engine in a closed building without
proper ventilation.
Z Do not smoke, use open flames, cause sparks in
the nearby area when filling fuel or handling highly
flammable liquids.
Z Do not use flames as light sources when working
on a machine or checking for leaks.
Z Move with caution when working under a Machine,
and also on or near a Machine. Wear proper safety
accessories:
helmets, goggles and special footwear.
Z During checks which should be carried out with the
engine running, ask an assistant to sit at the oper-
ator’s seat and keep the service technician under
visual control at any moment.
In case of operations outside the workshop, drive
the machine to a flat area and block it. If working
on an incline cannot be avoided, first block the Ma-
chine carefully. Move it to a flat area as soon as
possible with a certain extent of safety.
Z Ruined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always han-
dle them wearing gloves of proper thickness.
Z Chains should always be safely fastened. Ensure
that fastening device is strong enough to hold the
load foreseen. No persons should stop near the
fastening point, trailing chains or cables.
Z The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of water
or oil.
Z Do not pile up grease or oil soaked rags, as they
constitute a great fire hazard. Always place them
into a metal container. Before starting the Machine
or its attachments, check, adjust and block the op-
erator’s seat. Also ensure that there are no per-
sons within the Machine or attachment operating
range.
Z Do not keep in your pockets any object which
might fall unobserved into the Machine’s inner
compartments.

SECTION 00 - SAFETY PRECAUTIONS
Z Whenever there is the possibility of being reached
by ejected metal parts or similar, use protection
eye mask or goggles with side guards, helmets,
special footwear and heavy gloves. Wear suitable
protection such as tinted eye protection, helmets,
special clothing, gloves and footwear whenever it
is necessary to carry out welding procedures. All
persons standing in the vicinity of the welding proc-
ess should wear tinted eye protection. NEVER
LOOK AT THE WELDING ARC IF YOUR EYES
ARE NOT SUITABLY PROTECTED.
Z Metal cables with the use get frayed. Always wear
adequate protections (heavy gloves, eye protec-
tion, etc.).
Z Handle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective
equipment, such as eye protection, heavy gloves
and protective footwear.
START UP
Z Never run the engine in confined spaces which are
not equipped with adequate ventilation for exhaust
gas extraction.
Z Never bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
Z Always loosen the radiator cap very slowly before
removing it to allow pressure in the system to dis-
sipate. Coolant should be topped up only when the
engine is stopped or idle if hot.
Z Do not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case of
fuel spilling.
Z Never check or adjust the fan belt tension when the
engine is running. Never adjust the fuel injection
pump when the machine is moving.
Z Never lubricate the machine when the engine is
running.
ELECTRICAL SYSTEMS
Z If it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+) to
(+) and (-) to (-). Avoid short-circuiting the termi-
nals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave the
battery compartment uncovered to improve venti-
lation. Avoid checking the battery charge by
means of “jumpers” made by placing metallic ob-
jects across the terminals. Avoid sparks or flames
near the battery area. Do not smoke to prevent ex-
plosion hazards.
Z Prior to any service, check for fuel or coolant leaks.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci-
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5
dental explosion hazard due to build-up of gasses
relieved during charging.
Z Always disconnect the batteries before performing
any type of service on the electrical system.
HYDRAULIC SYSTEMS
Z Some fluid slowly coming out from a very small
port can be almost invisible and be strong enough
to penetrate the skin. For this reason, NEVER USE
YOUR HANDS TO CHECK FOR LEAKS, but use
a piece of cardboard or a piece of wood for this
purpose. If any fluid is injected into the skin, seek
medical aid immediately. Lack of immediate medi-
cal attention, serious infections or dermatitis may
result.
Z Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
Z Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
Z Keep off and stay at the tyre side when correcting
the inflation pressure.
Z Check the pressure only when the machine is un-
loaded and tyres are cold to avoid wrong readings
due to over-pressure. Do not reuse parts of recov-
ered wheels as improper welding, brazing or heat-
ing may weaken the wheel and make it fail.
Z Never cut, nor weld a rim with the inflated tyre as-
sembled.
Z To remove the wheels, block both front and rear
Machine wheels. Raise the Machine and install
safe and stable supports under the Machine in ac-
cordance with regulations in force.
Z Deflate the tyre before removing any object caught
into the tyre tread.
Z Never inflate tyres using flammable gases as they
may originate explosions and cause injuries to by-
standers.
REMOVAL AND INSTALLATION
Z Lift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that parts
are supported by appropriate slings and hooks.
Use lifting eyes provided to this purpose. Take
care of the persons near the loads to be lifted.
Z Handle all parts with great care. Do not place your
hands or fingers between two parts. Wear ap-
proved protective clothing such as safety goggles,
gloves and footwear.
Z Do not twist chains or metal cables. Always wear
protection gloves to handle cables or chains.
 Copyright ©

6 SECTION 00 - SAFETY PRECAUTIONS

IMPORTANT ECOLOGICAL CONSIDERATIONS

The following are recommendations which may be
of assistance:
Z Become acquainted with and ensure that you un-
derstand the relative legislation applicable to your
country.
Z Where no legislation exists, obtain information
from suppliers of oils, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and
nature and how to safely store, use and dispose of
these substances.

Helpful hints
Z Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
Z In general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
Z Modern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
Z Avoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubri-
cants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
Z Modern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
Z Do not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
Z Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Z Do not increase the pressure in a pressurized cir-
cuit as this may lead to a catastrophic failure of the
system components.
Z Protect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 01 - MAINTENANCE
 Copyright ©

2 SECTION 01 - MAINTENANCE

SECTION 01 - MAINTENANCE
All maintenance and repair operations described in
this manual should be carried out exclusively by au-
thorized workshops. All instructions detailed should
be carefully observed and special equipment indi-
cated should be used if necessary.
Everyone who carries out service operations de-
scribed without carefully observing these prescrip-
tions will be directly responsible of deriving
damages.
GENERAL
Clean the exterior of all components before carrying
out any form of repair. Dirt and dust can reduce the
efficient working life of a component and lead to
costly replacement.
Time spent on the preparation and cleanliness of
working surfaces will pay dividends in making the
job easier and safer and will result in overhauled
components being more reliable and efficient in op-
eration. Use cleaning fluids which are known to be
safe. Certain types of fluid can cause damage to O-
rings and cause skin irritation. Solvents should be
checked that they are suitable for the cleaning of
components and also that they do not risk the per-
sonal safety of the user.
Replace O-rings, seals or gaskets whenever they
are disturbed. Never mix new and old seals or O-
rings, regardless of condition. Always lubricate new
seals and O-rings with hydraulic oil before installa-
tion.
When replacing component parts, use the correct
tool for the job.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or
the end connections on the hose are damaged.
When installing a new hose, loosely connect each
end and make sure the hose takes up the designed
position before tightening the connection. Clamps
should be tightened sufficiently to hold the hose
without crushing and to prevent chafing.
After hose replacement to a moving component,
check that the hose does not foul by moving the
component through the complete range of travel.
Be sure any hose which has been installed is not
kinked or twisted.
Hose connections which are damaged, dented,
crushed or leaking, restrict oil flow and the produc-
tivity of the components being served. Connectors
which show signs of movement from the original
swagged position have failed and will ultimately sep-
arate completely.
A hose with a chafed outer cover will allow water en-
try. Concealed corrosion of the wire reinforcement
will subsequently occur along the hose length with
resultant hose failure.
Copyright ©
3
Ballooning of the hose indicates an internal leakage
due to structural failure. This condition rapidly dete-
riorates and total hose failure soon occurs.
Kinked, crushed, stretched or deformed hoses gen-
erally suffer internal structural damage which can
result in oil restriction, a reduction in the speed of
operation and ultimate hose failure.
Free-moving, unsupported hoses must never be al-
lowed to touch each other or related working surfac-
es. This causes chafing which reduces hose life.
O-RING FLAT FACE SEAL FITTINGS
When repairing O-ring face seal connectors, the fol-
lowing procedures should be observed.
SWARNING
Never disconnect or tighten a hose or tube that is
under pressure, if in doubt, actuate the operating le-
vers several times with the engine switched off prior
to disconnecting a hose or tube.
Release the fittings and separate the hose or tube
assembly, then remove and discard the O-ring seal
from the fitting.
Dip a new O-ring seal into clean hydraulic oil prior to
installation. Install a new O-ring into the fitting and,
if necessary, retain in position using petroleum jelly.
Assemble the new hose or tube assembly and tight-
en the fitting finger tight, while holding the tube or
hose assembly to prevent it from turning.
Use two suitable wrenches and tighten the fitting to
the specified torque according to the size of the fit-
ting.
NOTE: to ensure a leak-free joint is obtained, it is
important that the fittings are not over or under
torqued.
SHIMMING
At each adjustment, select adjusting shims, meas-
ure them individually using a micrometre and then
sum up recorded values.
Do not rely on measuring the whole shimming set,
which may be incorrect, or on rated value indicated
for each shim.
ROTATING SHAFT SEALS
To correctly install rotating shaft seals, observe the
following instructions:
Z let the seal soak into the same oil as it will seal for
at least half an hour before mounting;
Z thoroughly clean the shaft and ensure that the
shaft working surface is not damaged;

4 SECTION 01 - MAINTENANCE
Z place the sealing lip towards the fluid. In case of a
hydrodynamic lip, consider the shaft rotation direc-
tion and orient grooves in order that they deviate
the fluid towards the inner side of the seal;
Z coat the sealing lip with a thin layer of lubricant (oil
rather than grease) and fill with grease the gap be-
tween the sealing lip and the dust lip of double lip
seals;
Z insert the seal into its seat and press it down using
a flat punch. Do not tap the seal with a hammer or
a drift;
Z take care to insert the seal perpendicularly to its
seat while you are pressing it. Once the seal is set-
tled, ensure that it contacts the thrust element if re-
quired;
Z to prevent damaging the sealing lip against the
shaft, place a suitable protection during installa-
tion.
O-RINGS
Lubricate the O-rings before inserting them into their
seats. This will prevent the O-rings from rolling over
and twisting during mounting which will jeopardize
sealing.
BEARINGS
It is advisable to heat the bearings to 80 to 90 °C be-
fore mounting them on their shafts and cool them
down before inserting them into their seats with ex-
ternal tapping.
SPRING PINS
When mounting split socket spring pins, ensure that
the pin notch is oriented in the direction of the effort
to stress the pin.
Spiral spring pins should not be oriented during in-
stallation.
HARDWARE TORQUE VALUES
Check the tightness of hardware periodically.
Use the following charts to determine the correct
torque when checking, adjusting or replacing hard-
ware on the Backhoe loader.
IMPORTANT: Torque values listed are for general
use only. Make sure fastener threads are clean and
not damaged.
NOTE: a torque wrench is necessary to properly
torque hardware.
Copyright ©
NOTES FOR SPARE PARTS
Only genuine parts guarantee same quality, life,
safety as original components as they are the same
as mounted in production. Only the genuine spare
parts can offer this guarantee.
All spare parts orders should be complete with the
following data:
Z machine model (commercial name) and chassis
number;
Z engine type and number;
Z part number of the ordered part, which can be
found on the “Spare Parts Catalogue”, which is the
base for order processing.
NOTES FOR EQUIPMENT
Equipment which proposes and shows in this man-
ual are as follows:
Z studied and designed expressly for use on compa-
ny machines;
Z necessary to make a reliable repair;
Z accurately built and strictly tested to offer efficient
and long-lasting working means.
We also remind the repair personnel that having
these equipment means:
Z work in optimal technical conditions;
Z obtain best results;
Z save time and effort;
Z work more safely.
NOTICES
Wear limits indicated for some details should be in-
tended as advised, but not binding values. The
words “front”, “rear”, “right hand”, and “left hand” re-
ferred to the different parts should be intended as
seen from the operator’s seat oriented to the normal
sense of movement of the machine.
HOW TO MOVE THE MACHINE WITH THE
BATTERY REMOVED
Cables from the external power supply should be
connected exclusively to the respective terminals of
the Machine positive and negative cables using pli-
ers in good condition which allow proper and steady
contact.
Disconnect all services (lights, wind-shield wipers,
etc.) before starting the Machine.
If it is necessary to check the machine electrical sys-
tem, check it only with the power supply connected.
At check end, disconnect all services and switch the
power supply off before disconnecting the cables.
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 02 - TECHNICAL
SPECIFICATIONS

1. LOADER BACKHOE MODELS .................................................................................................................... 3

2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 9
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 12
6. LIFTING CAPACITIES................................................................................................................................ 15
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 18
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 19
 Copyright ©

2 SECTION 02 - TECHNICAL SPECIFICATIONS

1.
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 3

1. LOADER BACKHOE MODELS

580 Super R 590 Super R 695 Super R

Powershift O O O

Powershuttle O O /
Stabilizer sideshift O O O

Stabilizer centre pivot / / O

Cab O O O

Rops O / /
2WD O / /
4WD O O O

4WS / / O

Pilot control O O O

Mechanical control O O O

Engine Iveco 71 kW - 95 HP model F4GE0454C*D660 O / /

Engine Iveco 82 kW - 110 HP model F4GE0484C*D660 / O /
Engine Iveco 82 kW - 110 HP (4WS) model
/ / O
F4GE0484C*D655
 Copyright ©

4 SECTION 02 - TECHNICAL SPECIFICATIONS

2. IDENTIFICATION OF MAIN COMPONENTS

1. Loader bucket 13. Battery box

2. Loader arm 14. Hydraulic tank
3. Front axle 15. Swing cylinders
4. Fuel tank
5. Rear axle
6. Operator's compartment - cab
7. Engine guard
8. Backhoe boom
9. Backhoe dipper or telescopic dipper
10. Backhoe bucket
11. Backhoe sideshift carriage
12. Stabilizers
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 5

3. TECHNICAL SPECIFICATIONS
ENGINE - IVECO 95 HP - 71 KW MODEL F4GE0454C*D660 (580 Super R)
Power...................................................................................................................... 95 hp/ 71 kW, turbocharged
Type .......................................................................................................................................................... Diesel
No. of cylinders ................................................................................................................................................. 4
Bore ....................................................................................................................................................... 104 mm
Stroke..................................................................................................................................................... 132 mm
Displacement ....................................................................................................................................... 4500 cm3
Compression Ratio ................................................................................................................................... 17.5:1
Firing Order.............................................................................................................................................. 1.3.4.2
Idle Speed.................................................................................................................................. 850-950 rev/mn
Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/mn
Maximum “Full Load” Speed.................................................................................................. 2225-2275 rev/mn
Maximum Torque (CEE) ......................................................................................................................... 398 Nm

ENGINE - IVECO 110 HP - 82 KW MODEL F4GE0484C*D660 (590 Super R) D655 (695 Super R)
Power................................................................................... 110 hp/ 82 kW, turbocharged - Charge Air Cooled
Type .......................................................................................................................................................... Diesel
No. of cylinders ................................................................................................................................................. 4
Bore ....................................................................................................................................................... 104 mm
Stroke..................................................................................................................................................... 132 mm
Displacement ....................................................................................................................................... 4500 cm3
Compression Ratio ................................................................................................................................... 17.5:1
Firing Order.............................................................................................................................................. 1.3.4.2
Idle Speed.................................................................................................................................. 850-950 rev/mn
Maximum “No-Load” Speed................................................................................................... 2380-2480 rev/mn
Maximum “Full Load” Speed.................................................................................................. 2225-2275 rev/mn
Maximum Torque (CEE) ......................................................................................................................... 480 Nm

COOLING SYSTEM
Type .................................................................................................................................. Pressurized Full Flow
Fan Belt Type..................................................................................................................... 8 Groove Serpentine
Fan Belt Tension..................................................................................................................Automatic tensioner
Air Conditioning Compressor Belt.......................................................................................................... Single V
Air Conditioning Belt Tension...................................................................................................................Manual
Thermostat:
Starts to Open at........................................................................................................................................ 81 °C
Fully Open at.............................................................................................................................................. 96 °C
Radiator Cap.......................................................................................................................................... 0.90 bar

FUEL SYSTEM
Injection Pump Manufacture and Type ............................................................... Bosch Rotary VE 4/12 F1100L
Cold Start Device ............................................................................................................... Optional Grid Heater
Excess Fuel Device ............................................................................................................................ Automatic
Fuel Shut Off......................................................................................................................................... Solenoid
Lift Pump........................................................................................................................................... Mechanical
Fuel lift pump supply pressure to injection pump.................................................................................... 245 bar
Timing ........................................................................................................................... 1 mm (0.04”) lift @ TDC
 Copyright ©

6 SECTION 02 - TECHNICAL SPECIFICATIONS

TRANSMISSION (580 Super R)

Transmission TURNER Model COM-T4-2025 POWERSHUTTLE 4x4 = 4 Forward and 4 Reverse Gears
Torque Convertor Ratio............................................................................................................................. 2.38:1
Transmission DANA T16000 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears
Torque Convertor Ratio............................................................................................................................. 2.54:1

TRANSMISSION (590 Super R - 695 Super R)

Transmission DANA T16000 POWERSHIFT 4x2 = 4 Forward and 2 Reverse Gears
Torque Convertor Ratio............................................................................................................................. 2.54:1

ELECTRICAL SYSTEM
Alternator Type............................................................................................................BOSCH NCBI 28 90 amp
Battery Type......................................................................................... 95 amp hr (12V/900 CCA) SAE - Single
............................................................................................................ 60 amp hr (12V/600 CCA) SAE - Double
Battery Disconnect via the Isolator Switch ................................................................ on Negative/chassis cable
Regulator.......................................................................................................................................Transistorized
Ground (Earth) ...................................................................................................................................... Negative
Starting Motor......................................................................Positive Engagement, Solenoid Operated (2.7 kW)

BRAKES
Type ............................................................................................ Wet Multi-Discs x8 per Axle (x4 per half Axle)
Disc Diameter...................................................................................................................................... 203.2 mm
Parking Type .................................................................................................................. Single disc on driveline

STEERING
Power Steering Type......................................................................................................................... Hydrostatic
Power Steering Displacement 2WS ....................................................................................................125 cc/rev
Power Steering Displacement 4WS ....................................................................................................160 cc/rev
Turns Lock to Lock 2WD + 4WD......................................................................................... Left 3.25; Right 3.25
System Pressure...................................................................................................... 177 ± 3 bar (2567 ± 43 psi)

FRONT AXLE
Type (2WD)...................................................................................................... CARRARO mod. 26.00 steering
Type (4WD)........................................................................... CARRARO mod. 26.16 steering, single reduction
Type (4WS) ........................................................................... CARRARO mod. 26.28 steering, single reduction

REAR AXLE
Type (2WS) .............................................................................................. Double Reduction, Inboard Planetary
Type (4WS) .......................................................................... CARRARO mod. 26.32 steering, double reduction
Differential Lock (Powershuttle Transmission).................................................................................. Mechanical
Differential Lock (Powershift Transmission)....................................................................... Electrically Operated

HYDRAULIC SYSTEM
Hydraulic pump:
- Manufacturer.................................................................................................................................... CASAPPA
- Type ...........................................................Twin Gear Pump; Hydraulic System and Priority Steering System
- 95HP Model .......................................................................................................................KP30.34-0556-LMF
- 110HP Model .....................................................................................................................KP30.38-0556-LMF
Pump Displacement:
- 95 HP .....................................................................................................35.427 + 35.427 cm3/rev (34 + 34 cc)
- 110 HP ...................................................................................................40.258 + 35.427 cm3/rev (38 + 34 cc)
Hydraulic System Pressure:
Main Relief Valve Pressure............................................................................................................206 - 210 bar
Stabilizer Relief Valve Pressure.....................................................................................................196 - 202 bar
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 7

FRONT COUNTERWEIGHT
Weight.......................................................................................................................................................160 kg
RADIATOR COOLANTS
Anti-freeze should be changed every 2000 hours or 24 months.
In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits:
Total hardness ................................................................................................................... 300 parts per million
Chloride............................................................................................................................... 100 parts per million
Sulphates ............................................................................................................................ 100 parts per million
NOISE LEVEL
Certified by the manufacturer.
In accordance with European directive 2000/14/EC - Stage II.
Internal noise level (LpA) .................................................................................................................. 77 decibels
External noise level (LwA) (580 Super R)....................................................................................... 102 decibels
External noise level (LwA) (590 Super R - 695 Super R) ............................................................... 103 decibels
VIBRATION LEVEL INSIDE THE CAB
Upper members ........................................................................................................... level lower than 2.5 m/s²
Abdomen...................................................................................................................... level lower than 0.5 m/s²
LOADER BUCKET

Type Standard 4x1 6 x 1 (with forks)

Heaped capacity 1.0 m3 1.0 m3 1.0 m3
2WS

Width 2250 mm 2250 mm 2250 mm

Weight 400 kg 800 kg 960 kg
Heaped capacity 1.15 m3 1.15 m3 1.15 m3
4WS

Width 2400 mm 2400 mm 2400 mm

Weight 426 kg 830 kg 990 kg

BACKHOE BUCKET

Struck capacity SAE J 296 Width Weight

76 L 305 mm 108 kg
109 L 457 mm 130 kg
153 L 610 mm 160 kg
196 L 762 mm 180 kg
238 L 914 mm 208 kg
 Copyright ©

8 SECTION 02 - TECHNICAL SPECIFICATIONS

TYRES - 2WS

Front tyre Rear tyre

11L - 16 F3 12PR 18.4 - 26 R4 10PR
2WD
11L - 16 F3 12PR 16.9 - 28 R4 10PR
12.5/80 - 18 I3 18.4 - 26 R4 10PR
4WD 10.5/80 - 18 I3 16.9 - 28 R4 10PR
320/80 R18 IT 520 480/80 R26

TYRES - 4WS

Front and Rear tyre

16.9/24 R4 12PR
16.9/28 R4 12PR
440/80 R28 IT520
440/80 R28 IT530
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 9

4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE

580 Super R - 590 Super R (SIDESHIFT VERSION)

TYRES FRONT REAR

2WD (580 Super R) 11L-16F 18.4-26
4WD 12.5/80-18 18.4-26

2WD (580 Super R) with

Dimensions 4WD with standard bucket
standard bucket
A 4130 mm 4250 mm
B 3345 mm 3460 mm
C 2550 mm 2685 mm
D 45° 45°
E 45° 45°
F 875 mm 830 mm
G 2950 mm 2950 mm
H 240 mm 120 mm
I 2060 mm 1973 mm
J 2175 mm 2175 mm
K 1325 mm 1325 mm
L 1630 mm 1630 mm
M 5865 mm 5778 mm
N 4000 mm 4000 mm
P 2430 mm 2430 mm
Q 2250 mm 2250 mm
Performance 2WD (580 Super R) 4WD
Lift capacity at maximum height 3325 kg 3450 kg
Breakout force 6556 daN 6537 daN
 Copyright ©

10 SECTION 02 - TECHNICAL SPECIFICATIONS

695 Super R (SIDESHIFT VERSION)

TYRES FRONT REAR

440/80R28 440/80R28

Dimensions Standard bucket 4 in 1 bucket 6 in 1 bucket (with forks)

A 4347 mm 4460 mm 4460 mm
B 3491 mm 3518 mm 3518 mm
C 2717 mm 2753 mm 2753 mm
D 45° 45° 45°
E 45° 45° 45°
F 744 mm 690mm 690mm
G 2900 mm 2900 mm 2900 mm
H 113 mm 90 mm 90 mm
I 1975 mm 1980 mm 1980 mm
J 2200 mm 2200 mm 2200 mm
K 1324 mm 1324 mm 1324 mm
L 1630 mm 1630 mm 1630 mm
M 5783 mm 5788 mm 5788 mm
N 3935 mm 3935 mm 3935 mm
P 2480 mm 2480 mm 2480 mm
Q 2400 mm 2400 mm 2400 mm
Performance Standard bucket 4 in 1 bucket 6 in 1 bucket (with forks)
Lift capacity at 3386 kg 3075 kg 2950 kg
maximum height
Breakout force 5413 daN 5600 daN 5600 daN
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 11

695 Super R (CENTRE PIVOT VERSION)

TYRES FRONT REAR

16.9-28 16.9-28

Dimensions Standard bucket 4 in 1 bucket 6 in 1 bucket (with forks)

A 4347 mm 4460 mm 4460 mm
B 3491 mm 3518 mm 3518 mm
C 2717 mm 2753 mm 2753 mm
D 45° 45° 45°
E 45° 45° 45°
F 744 mm 690 mm 690 mm
G 2900 mm 2900 mm 2900 mm
H 113 mm 90 mm 90 mm
I 1975 mm 1980 mm 1980 mm
J 2200 mm 2200 mm 2200 mm
K 1324 mm 1324 mm 1324 mm
L 3040 mm 3040 mm 3040 mm
M 7220 mm 7225 mm 7225 mm
N 3935 mm 3935 mm 3935 mm
P 2230 mm 2230 mm 2230 mm
Q 2400 mm 2400 mm 2400 mm
Performance Standard bucket 4 in 1 bucket 6 in 1 bucket (with forks)
Lift capacity at 3386 kg 3075 kg 2950 kg
maximum height
Breakout force 5413 daN 5600 daN 5600 daN
 Copyright ©

12 SECTION 02 - TECHNICAL SPECIFICATIONS

5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE

580 Super R and 590 Super R (SIDESHIFT VERSION)

TYRES FRONT REAR

12.5/80-18 18.4-26

Dimensions standard dipper telescopic dipper (extended)

A 1828 mm 2757 mm
B 200° 204°
C 5837 mm 6537 mm
D 3917 mm 4645 mm
E 5906 mm 6992 mm
F 7231 mm 8317 mm
G 6454 mm 7540 mm
J 4612 mm 5799 mm
K 2280 mm 2280 mm
L 2790 mm 2790 mm
M 14° 14°
Performance standard dipper telescopic dipper (extended)
Swing arc 180° 180°
Maximum digging force - dipper cylinder 3623 daN 2581 daN
Maximum digging force - bucket cylinder 5234 daN 5234 daN
Lift capacity through dipper arc 1975 kg 1470 kg
Lift capacity, dipper 3.66 m above ground 2040 kg 1490 kg
Lift capacity at 4.26 m above ground 1590 kg 1040 kg
Telescopic dipper extension length - 1200 mm
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 13

695 Super R (SIDESHIFT VERSION)

TYRES FRONT REAR

440/80R28 440/80R28

Dimensions standard dipper telescopic dipper (extended)

A 1899 mm 2844 mm
B 200° 200°
C 5815 mm 6492 mm
D 3908 mm 4615 mm
E 5903 mm 6990 mm
F 7228 mm 8315 mm
G 6518 mm 7605 mm
J 4623 mm 5805 mm
K 2280 mm 2280 mm
L 2790 mm 2790 mm
M 14° 14°
Performance standard dipper telescopic dipper (extended)
Swing arc 180° 180°
Maximum digging force - dipper cylinder 3623 daN 2591 daN
Maximum digging force - bucket cylinder 5234 daN 5234 daN
Lift capacity through dipper arc 2260 kg 1610 kg
Lift capacity, dipper 3.66 m above ground 2325 kg 1610 kg
Lift capacity at 4.26 m above ground 1520 kg 1000 kg
Telescopic dipper extension length - 1200 mm
 Copyright ©

14 SECTION 02 - TECHNICAL SPECIFICATIONS

695 Super R (CENTRE PIVOT VERSION)

TYRES FRONT REAR

440/80R28 440/80R28

Dimensions standard dipper telescopic dipper (extended)

A 1870 mm 2855 mm
B 200° 200°
C 5737 mm 6421 mm
D 4002 mm 4686 mm
E 5836 mm 6922 mm
F 7161 mm 8247 mm
G 6346 mm 7432 mm
J 4556 mm 5738 mm
K 2280 mm 2280 mm
L 2790 mm 2790 mm
M 14° 14°
Performance standard dipper telescopic dipper (extended)
Swing arc 180° 180°
Maximum digging force - dipper cylinder 3744 daN 2643 daN
Maximum digging force - bucket cylinder 5603 daN 5603 daN
Lift capacity through dipper arc 2350 kg 1560 kg
Lift capacity, dipper 3.66 m above ground 2475 kg 1560 kg
Lift capacity at 4.26 m above ground 1470 kg 950 kg
Telescopic dipper extension length - 1200 mm
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 15

6. LIFTING CAPACITIES
580 Super R and 590 Super R (SIDESHIFT VERSION)

Telescopic dipper Telescopic dipper Height/

Standard dipper
(retracted) (extended) Depth
Dipper - A Boom - B Dipper - A Boom - B Dipper - A Boom - B m
610 +5.4
1200 1120 920 +4.9
1590 1490 1515 1040 +4.3
2040 1690 1930 1580 1490 1100 +3.6
1975 1710 1870 1590 1470 1125 +3.0
2010 1650 1900 1540 1490 1135 +2.4
2165 1560 2050 1440 1555 1135 +1.8
2630 1510 2495 1390 1685 1105 +1.2
3860 1490 3690 1370 1950 1090 +0.6
1500 1375 2785 1090 0 (ground)
1540 1405 3850 1100 -0.6
1530 1380 1110 -1.2
1520 1370 1115 -1.8
1540 1380 1125 -2.4
1605 1435 1155 -3.0
1875 1675 1210 -3.6
1360 -4.2
1930 -4.8
 Copyright ©

16 SECTION 02 - TECHNICAL SPECIFICATIONS

695 Super R (SIDESHIFT VERSION)

Telescopic dipper Telescopic dipper Height/

Standard dipper
(retracted) (extended) Depth
Dipper - A Boom - B Dipper - A Boom - B Dipper - A Boom - B m
570 +5.4
1120 1040 865 +4.9
1520 1415 1510 1000 +4.3
2325 1650 2215 1535 1610 1070 +3.6
2260 1680 2150 1560 1645 1105 +3.0
2300 1675 2190 1550 1670 1120 +2.4
2480 1660 2360 1530 1760 1125 +1.8
3015 1630 2885 1500 1885 1130 +1.2
4400 1605 4230 1470 2135 1125 +0.6
1580 1440 3250 1125 0 (ground)
1560 1415 4420 1120 -0.6
1550 1400 1125 -1.2
1550 1400 1130 -1.8
1575 1415 1145 -2.4
1660 1490 1180 -3.0
2025 1815 1245 -3.6
1420 -4.2
2155 -4.8
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 17

695 Super R (CENTRE PIVOT VERSION)

Telescopic dipper Telescopic dipper Height/

Standard dipper
(retracted) (extended) Depth
Dipper - A Boom - B Dipper - A Boom - B Dipper - A Boom - B m
605 +5.4
1075 990 905 +4.9
1470 1365 1460 950 +4.3
2270 1600 2165 1485 1560 1020 +3.6
2195 1630 2090 1510 1595 1055 +3.0
2240 1625 2135 1500 1620 1070 +2.4
2445 1610 2330 1480 1700 1075 +1.8
3090 1580 2960 1450 1835 1080 +1.2
4960 1555 4790 1420 2080 1075 +0.6
1530 1390 3425 1075 0 (ground)
1510 1365 5065 1070 -0.6
1500 1350 1075 -1.2
1500 1345 1080 -1.8
1525 1365 1090 -2.4
1610 1440 1130 -3.0
1970 1760 1195 -3.6
1370 -4.2
2105 -4.8
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18 SECTION 02 - TECHNICAL SPECIFICATIONS

7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE

580 Super R and 590 Super R
(A) Reach Full Height............................... 2319 mm
(B) Reach Ground Level .......................... 3186 mm
(C) Lift Height ........................................... 2998 mm
(D) Lift Height ........................................... 3458 mm
Fork Spacing - Minimum centres ............... 275 mm
Fork Spacing - Maximum centres ............ 1773 mm
Fork Length .............................................. 1026 mm
Fork Width.................................................... 80 mm

695 Super R
(A) Reach Full Height............................... 2194 mm
(B) Reach Ground Level .......................... 3186 mm
(C) Lift Height ........................................... 3059 mm
(D) Lift Height ........................................... 3518 mm
Fork Spacing - Minimum centres ............... 275 mm
Fork Spacing - Maximum centres ............ 1773 mm
Fork Length .............................................. 1026 mm
Fork Width.................................................... 80 mm
 Copyright ©

SECTION 02 - TECHNICAL SPECIFICATIONS 19

8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS

RECOMMENDED FLUIDS AND CASE INTERNATIONAL MODELS QUANTITY

APPLICATION Specifications Specifications
Litres
ENGINE - OIL
Akcela No 1 Engine oil (15W40) MS 1121 API CH-4, ACEA E5 2WS - with filter 14
4WS - with filter 12.8
COOLING SYSTEM
Akcela Premium Anti-freeze MS 1710 CUNA NC 956-16 ALL 24
antifreeze 50% water 50%
HYDRAULIC SYSTEM
Akcela Nexplore MAT 3525 API GL4 ISO VG 32/46 2WS 140
4WS 118

Akcela Hydraulic Excavator Fluid Bio MS 1230 ISO VG 46 2WS 140

DIN 51524 - part II 4WS 118
POWERSHUTTLE TRANSMISSION
Akcela Nexplore MAT 3525 API GL4 ISO VG 32/46 ALL 18
POWERSHIFT TRANSMISSION
Akcela Trans XHD ATF DEXRON III ALL 14
FRONT AXLE (2WS)
Akcela Hy-Tran Ultra MAT 3525 2WD (each) 0.2
Differential 6.5
4WD Wheel hub 0.7
(each)
FRONT AXLE (4WS) Differential 10.5
Akcela Nexplore MAT 3525 API GL4 ISO VG 32/46
Wheel hub (each) 1.3
REAR AXLE (2WS)
Akcela Hy-Tran Ultra MAT 3525 21.2
+
AOA Axle oil additive 0.8
REAR AXLE (4WS) Differential 11
Akcela Nexplore MAT 3525 API GL4 ISO VG 32/46
Wheel hub (each) 1.3
BRAKE MASTER CYLINDER
Akcela LHM Fluid ISO 7308 ALL 1
Mineral Oil
FUEL
Decanted and filtered Diesel Fuel 2WS 145
4WS 124
GENERAL LUBRICATION JOINTS
Akcela Multi-purpose grease 251H EP NLGI 2 ALL As required
TELESCOPIC DIPPER LUBRICATION
Akcela Moly Grease 251 H EP-M NLGI 2 ALL As required
AIR CONDITIONING COMPRESSOR
PAG Oil SP 20 ALL 240 cc
 Copyright ©

20 SECTION 02 - TECHNICAL SPECIFICATIONS

NOTE:
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 17 - TORQUE CONVERTERS

1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3

1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.1 DESCRIPTION AND OPERATION........................................................................................................ 7
2.2 TECHNICAL SPECIFICATIONS............................................................................................................ 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
 Copyright ©

2 SECTION 17 - TORQUE CONVERTERS

 Copyright ©

SECTION 17 - TORQUE CONVERTERS 3

1. POWERSHUTTLE TORQUE CONVERTER

1.1 DESCRIPTION AND OPERATION

The torque converter is the connection between the

engine and the transmission and is hydraulically ac-
tuated. The main parts of the torque converter (A)
are the impeller (pump), the turbine, the stator and
the front and rear covers. The impeller is integral
with the rear cover and is driven by the engine fly-
wheel by means of a drive plate.
The stator, is splined to a stationary shaft (stator
support) through a one-way clutch that permits the
stator to rotate only in the same direction as the im-
peller. All of the converter parts are enclosed in an
oil-filled housing. The front and rear cover, being
welded together, form the housing.
The turbine (2), splined to the front input shaft, is
splined to a stationary shaft (stator support) through
a one-way clutch that permits the stator (3) to rotate
only in the same direction as the impeller (1). All of
the converter parts are enclosed in an oil-filled hous-
ing. When the engine is running, the oil in the con-
verter flows from the impeller (1) to the turbine (2)
and back to the impeller through the stator (3). This
flow produces a maximum torque increase.
When enough oil flow is developed by the impeller,
the turbine begins to rotate, driving the front input
shaft. The torque multiplication gradually decreases
as turbine speed approaches impeller speed, and
becomes 1 to 1 when the turbine is being driven at
nine tenths impeller speed.

When the turbine (2) is rotating at approximately

nine tenths impeller speed, the converter stops mul-
tiplying torque because the oil is now acting on the
rear face of the stator blades (4). The action of the
oil on the rear face of the stator unlocks the one-way
clutch (5), permitting the stator to rotate in the same
direction as the turbine (2) and impeller (1). Through
this action the converter becomes an efficient fluid
coupling by transmitting engine torque from the im-
peller to the turbine. To achieve optimum operation
the engine performance, transmission ratios, hy-
draulic power delivery and converter torque multipli-
cation are all “Matched” to provide the necessary
vehicle drive torque when required. When the tur-
bine is rotating less than nine tenths impeller speed
(1), the converter is multiplying torque through the
action of the stator (3). This action, produced by oil
acting on the front face of the stator blades, tends to
rotate the stator in the opposite direction of the im-
peller (1) and turbine (2). However, the one-way
clutch prevents this opposite rotation and allows the
stator to direct oil back to the impeller, thereby pro-
ducing torque multiplication. Maximum torque multi-
plication is achieved when the impeller is driven at
stall speed and the turbine is stationary.
 Copyright ©

4 SECTION 17 - TORQUE CONVERTERS

1.2 TECHNICAL SPECIFICATIONS

Torque converter ratio............................................................................................................................... 2.38:1

Weight ..................................................................................................................................................... 17.4 kg
Torque of retaining screws for transmission .............................................................................................58 Nm
Torque of retaining screw for flywheel ......................................................................................................41 Nm
Torque of screw for drive plate to the convertor........................................................................................53 Nm
Torque of screw for drive plate to the flywheel..........................................................................................41 Nm

Hydraulic tests
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ............................................................................................................................. 80-85 °C
Cold start valve (For reference only)......................................................................................................... 26 bar
System pressure test .....................................................................................................................13.7-15.2 bar
Torque converter................................................................................................................................... 7-11 bar

1.3 OVERHAUL

The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque convert-
er cleaner may be used to clean the converter. How-
ever, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.

Z Drain as much oil as possible from the hub of the

converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning sol-
vent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the sol-
vent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the sol-
vent that is drained from the converter is clean.

1.4 INSPECTION

Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.
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SECTION 17 - TORQUE CONVERTERS 5

1.5 DISASSEMBLY AND ASSEMBLY

Z Secure the drive plate (3) to the torque converter

(5), with the attaching bolts and flat washers (1).
Z Tighten bolts to 53 Nm.
Z Prior to fitting the transmission place the torque
converter carefully over the transmission shaft and
into the transmission housing.
Z With the transmission bolted to the engine secure
the drive plate to the flywheel (6) accessed through
the starter motor aperture, with the attaching bolts
and washers (2). Tighten bolts to 41 Nm.

1.6 STALL TEST

The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are oper-
ating satisfactorily.
For the test to be conclusive, the transmission hy-
draulic pump and pressure regulating valve must be
operating correctly.
They can be checked by performing the “Line Pres-
sure Test”.
The engine and brakes must also be in good working
order.
Z Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as re-
quired to bring to the proper level.
Z With the gearshift lever and the shuttle lever in neu-
tral, start the engine and run at 800-1000 revs/min
until the transmission temperature reaches 29 °C -
35 °C.
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 revs/min, then
shift the power reversing lever to the forward posi-
tion. This will position the control valve so as to di-
rect high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral posi-
tion. The stall speed should be:
Engine 95 HP.......................... 1750 ÷ 1900 rev/min
Engine 110 HP........................ 1900 ÷ 2100 rev/min
 Copyright ©

6 SECTION 17 - TORQUE CONVERTERS

IMPORTANT: to prevent the transmission from

overheating, do not allow the engine to operate at
wide open throttle for more than fifteen seconds.

Z Allow the transmission oil to cool to 29 °C - 35 °C.

Check the rear hydraulic clutch by repeating previ-
ous steps, but with the power reversing lever in the
rearward position. Again, cool the transmission oil
by allowing the engine to run at approximately 1000
revs/min for one minute.
Z The engine speed noted previously (stall speed) for
both the front and rear clutch assemblies should be
within 150 revs/min of each other. If the stall speed
is not within these limits, refer to the diagnosis
guide for possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 revs/
min, then shift into any gear ratio. If the gears clash,
either the front or rear hydraulic clutch assembly is
transmitting power, even though the power revers-
ing lever is in neutral.

NOTE: if the unit creeps forward and the gears

clash, the front clutch is at fault. The rear clutch is at
fault if the unit creeps backward. If the unit does not
creep and the gears still clash, use the stabilizers to
raise the rear wheels off the ground, move the power
reversing lever to neutral and shift into first gear.
Check the rear wheels for rotational direction; if the
wheel rotate rearward, then the rear clutch is at fault.

1.7 FAULT FINDING

PROBLEM CAUSE ACTION

Low stall speed Hydraulic clutch not releasing
Stator support broken
Defective torque converter
Low engine power
High stall speed Hydraulic clutch not applying or is
slipping
Low line pressure
Sealing rings on rear input shaft
broken
Defective torque converter
Replace torque converter.
Replace torque converter.
Replace torque converter.
Check and correct output.
Replace.
Check pump output.
Replace seals.
Replace torque converter.

(See section “TRANSMISSION” chapter “TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST
POINTS” at page 18)
 Copyright ©

SECTION 17 - TORQUE CONVERTERS 7

2. POWERSHIFT TORQUE CONVERTER

2.1 DESCRIPTION AND OPERATION

Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the torque converter and is the primary component which starts the oil flow-
ing to the other components which results in torque multiplication. This element can be compared to a centrif-
ugal pump in that it picks up fluid at its centre discharges at its outer diameter. The torque converter turbine is
mounted opposite the impeller and is connected to the turbine shaft or clutch shaft. This element receives fluid
at its outer diameter and discharges at its centre. The stator of the torque converter is located between and at
the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is
exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation
into the impeller element. This recirculation will make the converter to multiply torque. The torque multiplication
in function of following elementes, impeller, turbine and stator, and the converter output speed (turbine speed).
The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is
at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multipli-
cation is increasing. In the impeller cover a splined shaft is fitted which runs inside and through the turbine shaft
to drive a hydraulic pump which is fitted at the back of the transmission. Since the shaft is connected to the
centre of the impeller cover, the pump speed will be the same as engine speed. The rear side of the impeller
cover has a tanged drive which drives the transmission charging pump located in the converter housing. The
transmission charging pump speed is also the same as the engine speed.

TORQUE CONVERTER AND LUBRICATION PRESSURE TEST PORTS

1. System pressure port 4. Oil temperature converter out port

2. Torque converter in port 5. Oil temperature cooler out port
3. Torque converter out port 6. Lubrication pressure port

(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 106)
 Copyright ©

8 SECTION 17 - TORQUE CONVERTERS

2.2 TECHNICAL SPECIFICATIONS

Torque converter ratio............................................................................................................................... 2.38:1

Torque of retaining screws for transmission .............................................................................................26 Nm
Torque of retaining screw for flywheel ......................................................................................................43 Nm
Torque of screw for drive plate..................................................................................................................43 Nm

Hydraulic tests
Tachometer setting .......................................................................................................................2200 revs/min
Test temperature, oil ............................................................................................................................. 82-93 °C
Torque converter relief valve..................................................................................................................... 10 bar
Oil temperature converter out:
Normal operating range .............................................................................................................. 80-90 °C
Maximum temperature ................................................................................................................... 120 °C

2.3 OVERHAUL

The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque convert-
er cleaner may be used to clean the converter. How-
ever, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.

Z Drain as much oil as possible from the hub of the

converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning sol-
vent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the sol-
vent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the sol-
vent that is drained from the converter is clean.
 Copyright ©

SECTION 17 - TORQUE CONVERTERS 9

2.4 INSPECTION

Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.

2.5 DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
Remove drive plate screws.

Remove drive plates.

Remove torque converter.

 Copyright ©

10 SECTION 17 - TORQUE CONVERTERS

ASSEMBLY
Install converter assembly on input shaft.

Install drive plates on converter.

Install drive plates screws and lock washers and

tighten screws to specified torque 43 Nm.
 Copyright ©

SECTION 17 - TORQUE CONVERTERS 11

2.6 STALL TEST

The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are oper- NOTE: if the unit creeps forward and the gears
ating satisfactorily. clash, the front clutch is at fault. The rear clutch is at
For the test to be conclusive, the transmission hy- fault if the unit creeps backward. If the unit does not
draulic pump and pressure regulating valve must be creep and the gears still clash, use the stabilizers to
operating correctly. raise the rear wheels off the ground, move the pow-
They can be checked by performing the “Line Pres- er reversing lever to neutral and shift into first gear.
sure Test”. Check the rear wheels for rotational direction; if the
The engine and brakes must also be in good work- wheel rotate rearward, then the rear clutch is at
ing order. fault.
Z Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as re-
quired to bring to the proper level.
Z With the gearshift lever and the shuttle lever in neu-
tral, start the engine and run at 800-1000 revs/min
until the transmission temperature reaches 29 °C -
35 °C.
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 revs/min, then
shift the power reversing lever to the forward posi-
tion. This will position the control valve so as to di-
rect high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral po-
sition. The stall speed should be:
Engine 95 HP.......................... 1750 ÷ 1900 rev/min
Engine 110 HP........................ 1950 ÷ 2200 rev/min

IMPORTANT: to prevent the transmission from

overheating, do not allow the engine to operate at
wide open throttle for more than fifteen seconds.

Z Allow the transmission oil to cool to 29 °C - 35 °C.

Check the rear hydraulic clutch by repeating previ-
ous steps, but with the power reversing lever in the
rearward position. Again, cool the transmission oil
by allowing the engine to run at approximately
1000 revs/min for one minute.
Z The engine speed noted previously (stall speed)
for both the front and rear clutch assemblies
should be within 150 revs/min of each other. If the
stall speed is not within these limits, refer to the di-
agnosis guide for possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 revs/
min, then shift into any gear ratio. If the gears
clash, either the front or rear hydraulic clutch as-
sembly is transmitting power, even though the
power reversing lever is in neutral.
 Copyright ©

12 SECTION 17 - TORQUE CONVERTERS

2.7 FAULT FINDING

PROBLEM CAUSE ACTION

Low stall speed
High stall speed
Hydraulic clutch not releasing
Stator support broken
Defective torque converter
Low engine power
Hydraulic clutch not applying or is
slipping
Low line pressure
Sealing rings on rear input shaft
broken
Defective torque converter
Replace torque converter.
Replace torque converter.
Replace torque converter.
Check and correct output.
Replace.
Check pump output.
Replace seals.
Replace torque converter.

(See section “TRANSMISSION” chapter “PRESSURE SPECIFICATIONS AND CHECK POINTS” at page 106)
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 21 - TRANSMISSION

1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3

1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER ............................................................................................................... 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION........................................................................ 133
2.11 TRANSMISSION COMPONENTS................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING.............................................................................................................................. 265
2.15 FAULT FINDING.............................................................................................................................. 267
 Copyright ©

2 SECTION 21 - TRANSMISSION
 Copyright ©

SECTION 21 - TRANSMISSION 3

1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025”

This transmission is used on Powershuttle loader
backhoes models 580 Super R and 590 Super R.
The transmission consists of a torque converter, an
internal rotor-type hydraulic pump, an oil distributor,
a solenoid control valve assembly, two hydraulically
operated clutches, a 4-speed synchromesh
geartrain, transmission case and oil cooler tubes.

NOTE: a conventional clutch is not used with this

transmission.

The transmission case serves as an oil tank for the

torque converter and hydraulic clutch assemblies.
The transmission receives power from the engine (1)
by a fluid coupling in the torque converter (2) and hy-
draulic clutch assemblies in the transmission (3).

1.1 TECHNICAL SPECIFICATIONS

GEAR RATIO

Forward Reverse
1 2 3 4 1 2 3 4
4.824 2.998 1.408 0.792 4.020 2.496 1.173 0.660

COLD START BY-PASS VALVE SPRING

Free length.......................................................................................................................... 53.4 mm ± 0.96 mm

FORWARD CLUTCH SPRING

Free length............................................................................................................................................ 76.6 mm

CLUTCH PISTON SPRING

Free length............................................................................................................................................ 75.9 mm

DETENT SPRING
Free length (Approximately)................................................................................................................ 42.06 mm
 Copyright ©

4 SECTION 21 - TRANSMISSION

END FLOAT
Input forward Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Input reverse Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Output shaft................................................................................................................ 1st Gear - 0.33-0.508 mm
.................................................................................................................................. 2nd Gear - 0.35-0.558 mm
...................................................................................................................................3rd Gear - 0.38-0.838 mm
................................................................................................................................... 4th Gear - 0.20-0.558 mm
Four Wheel Drive Shaft............................................................................................................... 0.050-0.28 mm
Bearing End Floats.................................................................................................................... 0.025-0.076 mm
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm

HYDRAULIC TESTS
Tachometer setting .......................................................................................................................2000 revs/min
Test temperature, oil ............................................................................................................................. 80-85 °C
Cold Start Valve (For reference only)........................................................................................................ 26 bar
System Pressure Test....................................................................................................................13.7-15.2 bar
Torque Converter ................................................................................................................................... 7-11 bar
Reverse Clutch...............................................................................................................................13.7-15.2 bar
Forward Clutch...............................................................................................................................13.7-15.2 bar
Four Wheel Drive Supply ...............................................................................................................13.7-15.2 bar

COOLER FLOW TEST

Oil temperature 80-85 °C ..............................................Revs/min .........................................Oil Flow Litres/min
...............................................................................................700 .......................................................12.5 litres
.............................................................................................1000 .......................................................18.2 litres
............................................................................................ 1500 .......................................................22.1 litres
............................................................................................ 2000 .......................................................24.0 litres
............................................................................................ 2200 .......................................................24.5 litres
.............................................................................................2500 .......................................................25.0 litres
 Copyright ©

SECTION 21 - TRANSMISSION 5

1.2 TIGHTENING TORQUES

Strainer bolts.................................................................................................................................... 18 to 31 Nm
Pump retaining bolts ........................................................................................................................ 18 to 31 Nm
Output Yoke bolts ............................................................................................................................ 68 to 88 Nm
Pressure test plugs .......................................................................................................................... 41 to 54 Nm
Main transmission case bolts........................................................................................................... 45 to 64 Nm
Shift detent plug ............................................................................................................................... 41 to 54 Nm
Shift fork screws............................................................................................................................... 18 to 25 Nm
Shift lever assembly screws.............................................................................................................16 to 24 Nm
Drain plugs....................................................................................................................................... 34 to 54 Nm
Relief valve ...................................................................................................................................... 23 to 30 Nm
Pressure regulator valve .................................................................................................................. 46 to 60 Nm
Cold start valve ................................................................................................................................ 46 to 60 Nm
4WD solenoid valve spool................................................................................................................20 to 27 Nm
4WD Solenoid coil retaining nut...............................................................................................................5.4 Nm
Control valve retaining screws ....................................................................................................... 6.8 to 8.5 Nm
4WD hydraulic pipe connections.................................................................................................. 6.8 to 10.2 Nm
Filter housing bolts...........................................................................................................................45 to 64 Nm
Oil filter............................................................................................................................................... 7 to 10 Nm
Temperature sender ........................................................................................................................ 20 to 27 Nm

RECOMMENDED SEALANTS
Transmission case joint ................................................................................................................... Loctite 5203
4WD Output gear ...............................................................................................................................Loctite 649
4WD gear (Permanent 4WD assy) .................................................................................................... Loctite 649
4WD clutch supply pipe ..................................................................................................................... Loctite 542
Gear lever housing...................................................................................................................Loctite 5900 RTV
Shimming access plug ....................................................................................................................... Loctite 649

6 SECTION 21 - TRANSMISSION
1.3 TRANSMISSION CONTROLS
4X4 POWERSHUTTLE TRANSMISSION CONTROLS
1. GEAR LEVER: Four gears are selectable for the
required ground speeds in both forward or re-
verse travel.
2. TRANSMISSION DISCONNECT BUTTON (On
gear level): Prior to changing gear depress and
hold down this switch which disengages trans-
mission drive, select the required gear with the
gear lever and release the switch to re-engage
drive.
3. LOADER ATTACHMENT CONTROL LEVER
4. TRANSMISSION DISCONNECT BUTTON: (On
loader attachment control lever) This button is
used to disengage the transmission in order to
increase loader attachment power.
Copyright ©
5. MECHANICAL DIFFERENTIAL LOCK PEDAL:
Depressing this pedal will lock both rear wheels
together giving equal drive and will disengage
when wheel torque equalises or foot brakes are
applied.
6. TRANSMISSION POWERSHUTTLE DIREC-
TION LEVER: Movement of this lever from the
neutral position will engage forward or rearward
travel and will cause the audible warning device
to sound.
NOTE: in reverse gear an audible alarm device
sounds.
7. WARNING HORN BOTTON
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SECTION 21 - TRANSMISSION 7

Transmission
The transmission is fully synchronised providing four
forward and four reverse speeds allowing gear ratio
changes on the move. A torque converter is used to
connect the engine to the transmission and the col-
umn mounted powershuttle lever (4) enables shifts
between forward and reverse travel without disen-
gaging gear ratios.
A “Transmission disconnect” feature is provided by
finger operated buttons (2) on both the main gear-
shift lever (1) and loader control lever (3) of which
disengages drive to the transmission to enable on
the move gear changing.

SWARNING
Always apply the parking brake whenever the ma-
chine is parked as the machine is free to roll even
though the transmission gearshift lever and power
reversing lever may be “In Gear” and the engine is
turned “OFF”.

Gear Shift Lever

The single gearshift lever (1) is used to select any
one of the four gear ratios. The transmission discon-
nect button (2) is depressed and held as the lever is
shifted from one gear to another and then released
to re-connect transmission drive.
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8 SECTION 21 - TRANSMISSION

Forward/Reverse Powershuttle Lever

To select FORWARD travel, engage the required
gear ratio with the gearshift lever, then with the en-
gine idling lift the shuttle lever from the neutral lock
position (1) and move to the forward position (2). Use
the foot throttle to control the engine and ground
speed.
To reverse the direction of travel, reduce engine
speed and move the power reversing from neutral
lock position (1) and rearwards (3) for reverse travel
an audible alarm device sounds.

NOTE: the shuttle lever is equipped with a neutral

lock to prevent inadvertent engagement of the trans-
mission. With this design the power reversing lever
moves through a “T” slot for the forward and reverse
positions.

IMPORTANT: when operating in low ambient tem-

peratures with cold transmission oil, allow the oil to
warm up before attempting to shift the shuttle lever.
The transmission can be shifted normally after the oil
warms up.

NOTE: the horn will sound if the shuttle lever is op-

erated (forward or reverse) with the handbrake en-
gaged.

NOTE: the shuttle lever can be shifted at any engine

speed, however, for safe, smooth operation the en-
gine speed should be reduced to approximately
1200 rev/min. This action is easily controlled by us-
ing the foot throttle to control engine and ground
speed.
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SECTION 21 - TRANSMISSION 9

Transmission Disconnect
The 4 x 4 transmission provides for easy upward and
downward gear ratio changes on the move. Howev-
er, as a clutch is not used between the engine and
transmission, the power flow from the engine to the
transmission must be interrupted to shift from one
gear ratio to another. This is accomplished by using
a transmission disconnect (dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.

SWARNING
To avoid personal injury do not use the disconnect
switch control to coast down hill. Excessive speed
may cause loss of control, personal injury to a by-
stander or failure of the transmission.

To make upward gear ratio changes simply depress

and hold the button (2) on the gearshift lever (1),
while moving the lever from one gear ratio to anoth-
er. When the desired gear ratio has been selected
release the button and allow the unit to gain engine
speed and ground speed. If another higher ratio is re-
quired repeat the procedure.

IMPORTANT: to avoid possible damage to the

transmission hydraulic clutches never use the dis-
connect switch for inching the machine forward.
Inching the machine forward with the button will
cause the clutches to slip excessively and overheat.

To make downward gear ratio changes or reduce

ground speed, simply lower the engine speed, de-
press and hold the gearshift lever button and down-
shift the transmission.
When the desired gear ratio has been selected re-
lease the button and adjust the engine speed to suit
ground speed required.
Operating the machine in too high a gear or under
too heavy a load will cause the torque converter to
slip excessively and overheat. If the machine is over-
loaded, the engine speed will not exceed a range of
1800-2200 rev/min at maximum throttle and the
torque converter will “stall” bringing the machine to a
complete stop.
If “stall” does occur, there is still sufficient engine
power to operate the loader however, to prevent the
transmission from overheating, either reduce the
load on the machine or select a lower gear ratio.
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10 SECTION 21 - TRANSMISSION

IMPORTANT: operating at a “stall” for more than 20

seconds can cause the transmission to overheat and
can possibly damage the transmission. If the trans-
mission overheats, the indicator needle rises into the
red zone. Shift both the power reversing and gear-
shift levers to neutral. Idle the engine at 1000 rev/
min. until the transmission oil is cooled sufficiently for
the indicator needle to drop into the green zone.
Once done, operations may resume.

DIFFERENTIAL LOCK PEDAL

In conditions inducing wheel slip, hold down the dif-
ferential lock pedal with your heel until the lock is felt
to engage. The lock will automatically disengage
when traction at the rear wheels equalizes. If a rear
wheel spins at speed, reduce the engine speed to
idle before engaging the differential lock to minimize
shock loads on the rear axle.

SWARNING
Never use the differential lock at speeds above 8 km/h
or when turning the machine.
When engaged the lock will prevent the machine turn-
ing and personal injury could result.
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SECTION 21 - TRANSMISSION 11

1.4 LUBRICATION

To ensure proper lubrication and operating temperatures it is most important that appropriate lubricants are
used and that the correct oil level is maintained.

Oil level checking

The oil level should be checked daily and corrected if necessary.
The oil level must be checked with the engine idling and with the transmission oil cold.
In this condition the oil level should fall between the Max and Min marks on the dipstick.
At normal operating temperature, (80 Deg.C.) the oil level will rise to 20 - 30 mm above the maximum mark on
the dipstick.

Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the
churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports
and build up on splines and bearings. Overfilling may also cause oil leaks.

Oil changes
An initial oil change and flush is recommended after the transmission is placed in actual service.
This change should be made at any time following 50 hours in service, but should not exceed 100 hours.
When changing the oil it is essential to renew the oil filter and clean out the suction strainer.
The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear. Minute par-
ticles of metal, the result of normal wear in service are deposited in and circulated with the oil. Oil changes are
best carried out when the transmission is thoroughly warm.

SWARNING
To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle, it is imperative that
the propeller shafts are disconnected.
Failure to observe this precaution may result in extensive damage to the transmission.

Oil capacity: 18 litres

Suggested oil:
10W or 10W30 Grade mineral oils or automatic transmission fluids which meet at least one of the following
specifications are allowable for use in ambient temperatures of between -20 and 40 Deg.C:
Akcela Nexplore MAT3525.
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12 SECTION 21 - TRANSMISSION

1.5 TRANSMISSION OIL FLOW AND SUPPLY

F29967

Pressure oil
Disengaged
Lubrication
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SECTION 21 - TRANSMISSION 13

OIL FLOW AND SUPPLY IN NEUTRAL POSITION

1 2 3 4 5

16

F R

15

6
14

13

12

11 10 9 8

F29968

Pump pressure Lubrication

Return to Sump
Torque converter flow
1. Shuttle control solenoid valve oil 14 bar.
2. Torque Converter - Receives low pressure cir-
cuit oil at maximum 10 bar and returns oil to port
(10).
3. Backhoe Boom Lock oil flow 14 bar.
4. Pressure filter - Mounted to the left of the trans-
mission viewed looking forward.
5. FWD - Low pressure circuit oil supply received
from the filter at 14 bar and fed by external tube
to rear of transmission to the FWD.
Suction
6. Cold Start Pressure protection Valve - Prevents
system pressure exceeding 26 bar at initial cold
start.
7. Oil Pump Port OUT, to oil filter assembly
through internal drillings.
8. Oil returned from the oil cooler lubricates shafts,
gears and bearings and returns oil to tank.
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14 SECTION 21 - TRANSMISSION

OIL FLOW AND SUPPLY IN FORWARD POSITION

1 2 3 4 5

16

F R

15

6
14

13

12

11 10 9 8

F29969

Pump pressure Lubrication

Return to Sump Suction
Torque converter flow
1. Returned lubrication oil from the pump shaft 7. Torque Converter pressure regulating valve, re-
bush to tank. ceives oil from the sequencing valve (16) and
2. Torque Converter oil supply IN, received at returns oil in excess of 10 bar to tank.
maximum 10 bar. 8. System pressure sequencing valve - Maintains
3. Transmission Tank/System Capacity: 17 litres circuit oil at 14 bar and supplies a continuous oil
(2WD) 18 litres (4WD). feed to the torque converter regulating valve.
4. Oil Cooler - Mounted below the engine coolant
radiator.
5. Oil pump suction port IN, from the tank.
6. Torque Converter oil OUT, to oil cooler.
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SECTION 21 - TRANSMISSION 15

TRANSMISSION OIL SUPPLY PORT

Viewed From Front and Rear Housings

1. Oil supply port to Reverse clutch pack, rear cas- 10. System pressure sequencing valve.
ing. 11. Torque converter pressure regulating valve.
2. Oil supply port to forward clutch pack, rear cas- 12. Oil supply from pump to solenoid valve pack.
ing. 13. Oil supply port to Reverse clutch pack, front cas-
3. Oil supply port to pressure test reverse clutch ing.
pack. 14. Oil port to tank (dump) from solenoid.
4. Oil supply port too pressure test forward clutch 15. Oil supply port to Reverse clutch pack, front cas-
pack. ing.
5. Front Wheel Drive Solenoid. 16. Oil supply port to forward clutch pack, front cas-
6. System pressure test point, connected to test ing.
block. 17. Oil supply port to forward clutch pack, front cas-
7. Locating Dowel ing.
8. Cold start oil pressure protection valve. 18. Manufacturing drilling only.
9. Torque converter pressure test point, connected 19. Forward oil supply port (front casing)
to test block. 20. Forward oil supply port (rear casing)
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16 SECTION 21 - TRANSMISSION

TRANSMISSION OIL FLOW THROUGH SOLENOID VALVE

The solenoid valves forward (1) or reverse (2) fitted
at the top of the transmission housing controls the oil
flow to the forward/reverse clutch packs in the tran-
mission.

On the underside of the solenoid valve are the 4

ports for directional oil flow to and from the solenoid
valve.
1. Oil supply from the valve to the forward clutch
pack
2. Return oil to tank
3. Oil supply from the valve to the reverse clutch
pack
4. Oil supply from the pump into the valve
5. Locating Pin

When the shuttle lever in the cab is in neutral position

the solenoid valve spool (1) will be static and oil (2) 1 2
will not flow into either reverse (3) or forward (4)
clutch pack oil gallery.

4 3 F29973

When forward direction is selected on the shuttle le-

ver the solenoid valve spool (1) will move to the left 1 2
(as shown) and the oil (2) will flow into the forward
clutch pack oil gallery (4).
When reverse direction is selected on the shuttle le-
ver the solenoid valve spool (1) will move to the right
(not shown) and the oil (2) will flow into the reverse
clutch pack oil gallery (3).

4 3
F29974
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SECTION 21 - TRANSMISSION 17

OIL FLOW SOLENOID CONTROL VALVE OPERATION (FORWARD DRIVE ONLY SHOWN)
The solenoid valve when in neutral position dead
heads the oil flow at the spool (1) from the supply 1
port and no oil is allowed to pass through the valve.
Therefore the oil in the galleries beyond the spool at
the fill time metering valve (2) remains static.

3
F29975

Selection of the forward / reverse shuttle lever in the

cab directs a current flow to the forward or reverse 1
solenoid and the spool (1) will move in the direction
selected, reverse shown. The oil then flows past the
spool to the clutch pack and applies pressure to the
fill time metering valve (2), a small bore allows oil to
flow into the clutch feathering valve.
When valve (2) moves it partially uncovers a port to
the tank and also opens the control orifice within the 2
valve. Therefore a precisely metered flow of oil is fed
to the pressure regulating (feathering) piston (3). As
this piston is pushed back against its spring the pres- 3
sure at the clutch builds up gradually to give a F29976

smooth jerk free clutch engagement.

When the piston reaches the end of its travel, clutch
pressure quickly builds up to full system pressure ei- 1
ther side of valve (2) so the light spring pushes the
valve covering the port to the tank.
The oil is dead headed at system pressure at the
clutch so ensuring full torque can be transmitted by
the clutch.

3
F29977

NOTE: the control valve also includes a pressure Regulated Pressure Oil
regulating (feathering) valve and a fill time metering Return Oil
valve for the reverse clutch pack. Pressure Oil
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18 SECTION 21 - TRANSMISSION

1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS

NOTE: all pressure test ports are 9/16 in UNF thread

size.

1. Cold Start oil pressure relief valve 10. Torque converter pressure regulating valve
26 bar reference only 7-11 bar
2. Forward Solenoid valve 11. Oil in from cooler, test port
13.7-15.2 bar 3.5 bar
3. Test port for reverse clutch pack 12. Backhoe Boom Lock supply
13.7-15.2 bar 13.7-15.2 bar
4. Test port for forward clutch pack 13. System pressure test point
13.7-15.2 bar 13.7-15.2 bar
5. System pressure sequencing valve 14. Converter pressure oil test port
13.7-15.2 bar 7-11 bar
6. Oil flow OUT to cooler 15. Front Wheel Drive Solenoid
7. Oil OUT to cooler, test port 13.7-15.2 bar
6.5 bar 16. Oil Filter
8. Front Wheel Drive test point 17. Reverse Solenoid valve
13.7-15.2 bar 13.7-15.2 bar
9. Oil flow IN from cooler
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SECTION 21 - TRANSMISSION 19

1.7 TRANSMISSION POWER FLOW

When neutral is selected on the shuttle lever (1), the

transmission forward (3) and reverse hydraulic
clutch packs or (4) are free to rotate and hence there
is no drive in the transmission.

With Forward or Reverse selected on the shuttle le-

ver (1) power will be directed through the clutch
packs (3) or (4) to the gear train and selection of gear
on lever (2) will result in engagement of gears to the
output shafts.

Power for all four forward gear ratios is transmitted

from the front hydraulic clutch (3) on the input shaft.
The input shaft then transmits power to the counter
shaft forward gear and the countershaft in turn trans-
mits power to the output shaft.

Power flow for all four reverse gear ratios is the same
as for all four forward gear ratios except that the rear
clutch (4) is engaged to transmit power to the reverse
idler gear. The reverse idler gear in turn transmits
power to the gear on the countershaft and in turn
transmits power to the output shaft.

Because power is being transmitted through the re-

verse idler gear, the countershaft and output shaft
will rotate in the opposite direction as for forward
gear ratios. The rear input shaft will also rotate in the
opposite direction.
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20 SECTION 21 - TRANSMISSION

F29980

Input Output
Intermediate
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SECTION 21 - TRANSMISSION 21

NOTE: four wheel drive shown.

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22 SECTION 21 - TRANSMISSION

NOTE: four wheel drive version shown.

 Copyright ©

SECTION 21 - TRANSMISSION 23

1.8 TRANSMISSION 2WD COMPONENTS

F27510
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24 SECTION 21 - TRANSMISSION

F27511
 Copyright ©

SECTION 21 - TRANSMISSION 25

1. Front gear case assembly 72. Circlip

2. Rear gear case assembly 73. Spring retainer
3. Plug and O-ring 74. Piston return spring
4. Cold start spring housing 75. Piston
5. Bolt 76. Piston sealing ring outer
6. Sealing cap 77. O-ring
7. Bolt 78. Piston sealing ring inner
8. Reverse shift hub sleeve 79. O-ring
9. Synchronizer assembly 80. Breather plug
10. Sealing ring 81. Capscrew
11. Copper washer 82. Breather
12. Thrust bearing 83. Needle bearing spacer
14. Thrust washer 84. Bolt
17. Ball 85. Needle bearing
18. Cold start spring 86. Temperature sender
19. O-ring 87. Output yoke washer
20. Plug 88. O-ring
21. Oil filter housing 89. Screw
22. Flywheel housing 90. O-ring
23. Washer 91. End yoke assembly
24. Filter housing gasket 92. Pump assembly
25. Bolt 93. Pump sealing ring
26. Cover plate 94. O-ring
27. Setscrew 95. Detent ball
28. 4th gear output shaft 96. Detent spring
29. 3rd gear output shaft 97. 1st/2nd shift fork
30. 2nd gear output shaft 98. 3rd/4th shift fork
31. 1st gear output shaft 99. 1st/2nd shift rod
32. Spacer 100. 3rd/4th shift rod
33. Bearing 101. Shift fork screw
34. 1st gear bearing spacer 102. Gear shift lever
35. 1st gear bearing sleeve 103. Bolt
36. Circlip 104. Gear lever seating
37. Expansion plug 105. Pin
38. Directional valve 106. Rubber boot
40. O-ring 107. O-ring
43. 4th gear thrust washer 108. Suction strainer
44. Bearing spacer 109. Pressure regulator valve
45. Shim 110. Plastic clip
50. Shim 111. Plastic clip
51. Bearing 112. Plug
52. Output shaft 113. Converter relief valve
53. Bearing 114. Setscrew
54. Bearing spacer 115. Oil seal
55. Shim 116. Oil filter
58. Shim 117. Oil filter adapter
59. Support washer 118. Drain plug
60. Bearing 120. Dowel
61. Bearing 121. Strainer cover plate
62. Thrust washer 127. Plug
63. Countershaft
64. Reverse idler gear
65. Input shaft assembly
66. Forward primary gear
67. Reverse primary gear
68. Clutch pack retaining clip
69. Clutch pack retaining plate
70. Clutch plate
71. Clutch plate (friction)
 Copyright ©

26 SECTION 21 - TRANSMISSION

1.9 TRANSMISSION 4WD COMPONENTS

F27512
 Copyright ©

SECTION 21 - TRANSMISSION 27
 Copyright ©

28 SECTION 21 - TRANSMISSION

1. Front gear case assembly 70. Clutch plate - steel

2. Rear gear case assembly 71. Clutch plate - friction
3. Plug assembly 72. Circlip
4. Bolt 73. Spring retainer
5. Bolt 74. Piston return spring
7. Bolt 75. Clutch piston
8. Reverse shift hub sleeve 76. Piston sealing ring
9. Synchronizer assembly 77. O-ring
10. Sealing ring 78. Piston sealing ring
11. Copper washer 79. O-ring
12. Thrust bearing 80. Brake caliper bolt
13. 4WD piston sealing ring 81. End yoke
14. Support washer 82. Spacer ring
15. Torque converter 83. Needle bearing spacer
16. O-ring 4WD piston 84. Bolt
17. Circlip 85. Needle bearing
18. Clutch collar 86. Bearing
19. Spring 4WD 87. Output flange washer
21. Spring support 89. Screw
22. Flywheel housing 90. O-ring
23. Parking brake assembly 91. Brake flange assembly
24. 4WD shaft 92. Pump assembly
25. 4WD gear 93. Sealing ring
26. Converter drive plate 94. Sealing ring
27. Thrust washer 95. Detent ball
28. 4th gear output shaft 96. Detent spring
29. 3rd gear output shaft 97. 1st/2nd shift fork
30. 2nd gear output shaft 98. 3rd/4th shift fork
31. 1st gear output shaft 99. 1st/2nd shift rod
32. 4WD gear output shaft 100. 3rd/4th shift rod
33. Bearing 1st gear output shaft 101. Shift fork screw
34. Bearing spacer 102. Gear stub lever
35. Bearing sleeve 103. Bolt
36. Circlip 104. Gear lever seating
37. Sealing ring 4WD shaft 105. Pin
38. Bearing spacer 106. Rubber boot
39. Shim 107. Washer
42. Shim 109. Hydraulic pipe nut
43. Thrust washer 110. Plastic clip
44. Bearing spacer 111. Plastic clip
45. Shim 112. Plug
50. Shim 113. Converter relief valve
51. Bearing 114. Setscrew
52. Output shaft 115. Banjo bolt washer
53. Bearing 116. 4WD clutch supply pipe
54. Bearing spacer 118. Drain plug assembly
55. Shim 119. Hydraulic pipe sleeve
58. Shim 120. Bearing spacer
59. Bearing 121. Shim
60. Bearing 124. Shim
61. Bearing 125. Cold start spring housing
62. Thrust washer 126. Coaxial drive shaft
63. Countershaft 127. Capscrew
64. Reverse idler gear 128. Pressure regulator valve
65. Input shaft assembly coaxial 129. 4WD solenoid valve
66. Forward primary gear 130. Directional control valve
67. Reverse primary gear 131. Oil filter
68. Clutch pack retaining ring 132. Oil filter adapter
69. Clutch pack retaining plate 134. Dowel
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SECTION 21 - TRANSMISSION 29

135. Oil seal

136. Sealing cap
137. Suction strainer
138. O-ring suction strainer
139. Support washer
140. Strainer cover plate
141. Setscrew
142. Breather
143. O-ring
146. O-ring
149. Expansion plug
150. Brake caliper nut
151. Pump mounting stud
152. Oil filter housing
153. Filter housing gasket
154. Bolt
155. O-ring
156. Cold start spring
157. Ball
158. Setscrew
160. Setscrew
161. Copper washer
162. Banjo bolt
163. Remote test port assembly
164. Remote test port pipe
165. Remote test port pipe
168. Pump mounting stud nut
170. 4WD gear bearing
171. Spacer 4WD gear bearings
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30 SECTION 21 - TRANSMISSION

SOLENOID VALVE COMPONENTS

1. Solenoid Retainer
2. Dirt Seal 12. Circlip
3. Solenoid 13. Clutch fill metering valve
4. Washer 14. Spring
5. Solenoid Body 15. Spool
6. Guide 16. Piston Clutch fill
7. Spring 17. Spring
8. Solenoid Pin 18. Retainer
9. Seal 19. Spring
10. Support Body Solenoid 20. Seal
11. End Cap 21. End Plug
 Copyright ©

SECTION 21 - TRANSMISSION 31

1.10 TRANSMISSION REMOVAL

Remove the transmission and engine as a complete

unit from the vehicle and place on a suitable stand for
disassembly.

NOTE: prior to disassembly drain the oils into suita-

ble containers for disposal.

Prior to separating the transmission from the engine.

Remove the starter motor (1).
Engine timing tab (2).
Torque converter back plate attaching bolts through
the starter motor aperture (1).
Bell housing attachment bolts (3).

IMPORTANT: prior to positioning the transmission

vertically remove the vehicle system oil pump (4) and
torque converter unit (5) from the transmission bell
housing (3).

Using eye bolts (1), one on each side capable of lift-

ing a weight of 250 kg hoist the transmission vertical-
ly and place in a safe, clean and suitable workshop
environment.
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32 SECTION 21 - TRANSMISSION

1.11 DISASSEMBLY AND ASSEMBLY

TRASMISSION DISASSEMBLY
Invert the transmission on a suitable bench.
For convenience the bench top should have a hole
in it to accommodate the input shaft and pump. Re-
move 3 screws and withdraw the gear shift lever as-
sembly.

Remove the plastic plugs and 4 cap screws and

withdraw the direction control valve.

Remove the converter relief valve.

 Copyright ©

SECTION 21 - TRANSMISSION 33

Remove the pressure regulator valve.

Remove the cold start housing, spring and ball.

Remove the temperature sender.

Remove the bolt, washer and O-ring and withdraw

the output yoke.
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34 SECTION 21 - TRANSMISSION

Remove the bolt, washer and O-ring and withdraw

the 4 wheel drive yoke and spacer (not fitted on 2
wheel drive model).

Remove 17 screws and using a suitable hoist take

off the rear transmission case.
Lever slots are provided to assist removal.

NOTE: the bearing cones and shims may fall from

the rear case during removal.

IMPORTANT: for proper reassembly, take note and

mark which bearings and shims come from which lo-
cations.

Remove the 4 wheel drive shaft assembly (not fitted

on 2 wheel drive model).

Tilt the countershaft and withdraw the input shaft as-

sembly.
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SECTION 21 - TRANSMISSION 35

Remove the reverse idler shaft assembly.

Remove the outer detent plug, spring and ball.

Ensure both synchronizers are in the neutral posi-

tion then remove the 1st/2nd shift fork screw.

Withdraw the 1st/2nd shift rod from the housing.

Then using a magnetic probe remove the interlock
ball from the detent, bore.
 Copyright ©

36 SECTION 21 - TRANSMISSION

Remove the 3rd/4th shift fork screw.

NOTE: before attempting to remove the 3/4th shift

rail, replace the detent plug as the ball and spring
may shoot out and cause injury.

Turn the 3rd/4th shift rod through 90 degrees and

withdraw from the housing.

Remove the detent plug, inner detent ball and

spring.

Remove the counter shaft assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 37

Remove the 1st/2nd and 3rd/4th shift forks.

Remove the output shaft assembly.

Remove the 4th gear lock out screw (if fitted).

Remove 2 screws and withdraw the strainer cover,

O-ring, spacer and strainer.
 Copyright ©

38 SECTION 21 - TRANSMISSION

Using a strap wrench remove and discard the oil fil-

ter.

Remove 2 bolts and take of the oil filter housing and

gasket.

Remove the 4 wheel drive solenoid coil and retain-

ing nut (only fitted on 4WD model).

Remove the 4 wheel drive solenoid spool (only fitted

on 4WD model).
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SECTION 21 - TRANSMISSION 39

Remove and discard the expansion plug from the

shimming access hole.

Invert the case. Remove 4 screws and copper wash-

ers then withdraw the pump assembly and sealing
ring.
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40 SECTION 21 - TRANSMISSION

INPUT SHAFT DISASSEMBLY

Position the shaft in a soft jawed vice as shown.

Remove and discard the 3 sealing rings.

Using the appropriate bearing puller 380002683 re-

move the rear bearing.

Remove the thrust washer and needle bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 41

Remove the reverse primary gear.

Remove the bearing, spacer, bearing and thrust

washer.

Remove the clutch pack retaining ring.

Remove the clutch pack retaining plate.

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42 SECTION 21 - TRANSMISSION

Remove the clutch pack.

Using the appropriate tool 380002689 compress the

piston spring and release the circlip.

Remove the circlip, retainer and spring.

Using pliers, as shown, pull the piston out of the

drum.
 Copyright ©

SECTION 21 - TRANSMISSION 43

Invert the shaft and remove the sealing ring.

Repeat steps described above to dismantle the for-
ward clutch pack.

Remove and discard the piston sealing rings and O-

rings.
 Copyright ©

44 SECTION 21 - TRANSMISSION

INPUT SHAFT ASSEMBLY

Re-new the piston sealing rings and O-rings.
To assist assembly bend the inner sealing ring into
a heart shape as shown.

Using transmission fluid to lubricate the seals push

the piston into the drum.

Replace the spring, retainer and circlip as shown.

Using the tool 380002689 compress the spring and

locate the circlip into its groove.
 Copyright ©

SECTION 21 - TRANSMISSION 45

Replace an externally splined (plain) disc and then

an internally splined (friction) disc alternately until six
of each have been replaced.

Replace the clutch pack retaining plate and refit the

retaining clip.

Replace the thrust washer, bearing, spacer and

bearing.

Line up the clutch plate splines and replace the pri-

mary gear. Then replace the needle bearing and
thrust washer as shown.

NOTE: the needle bearing should be fitted with the

closed side of its cage against the gear.
 Copyright ©

46 SECTION 21 - TRANSMISSION

Using an appropriately sized tube replace the bear-

ing as shown.

Invert the shaft and repeat previous operation. Then

fit a new sealing ring as shown.

Finally fit 3 new sealing rings to the rear of the shaft

as shown. (To avoid damage the sealing rings
should be left off until all shimming operations have
been completed).
 Copyright ©

SECTION 21 - TRANSMISSION 47

DISASSEMBLY AND ASSEMBLY OF THE

COUNTERSHAFT
The countershaft assembly.

Using the appropriate bearing pullers 380002691

and 380002687 remove the countershaft front and
rear bearings.

Using an appropriately sized tube replace the coun-

tershaft front and rear bearings.
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48 SECTION 21 - TRANSMISSION

DISASSEMBLY AND RE-ASSEMBLY OF THE

REVERSE IDLER SHAFT
The reverse idler assembly.

Using the appropriate bearing puller 380002683 re-

move the front and rear bearings.

Using an appropriately sized tube replace the front

and rear bearings.
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SECTION 21 - TRANSMISSION 49

OUTPUT SHAFT DISASSEMBLY

Position the shaft assembly in a soft jawed vice as
shown.

Using the appropriate bearing puller 380002686 re-

move the front bearing.

Remove the thrust washer and 4th gear.

Remove the 3rd/4th synchro assembly.

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50 SECTION 21 - TRANSMISSION

Remove the circlip and synchro hub.

Remove the 3rd gear.

Invert the shaft and using the appropriate bearing

puller 380002687 remove the rear bearing.

Remove the 4 wheel drive gear. (On 2WD models a

spacer is fitted in place of a gear).
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SECTION 21 - TRANSMISSION 51

Remove the 1st gear.

Remove the needle bearings and spacer.

Remove the 1st/2nd synchronizer assembly.

Using a suitable bearing puller or press.

Remove the bearing sleeve, synchro hub and 2nd
gear.
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52 SECTION 21 - TRANSMISSION

Remove the bearing sleeve, synchro hub and 2nd

gear.
 Copyright ©

SECTION 21 - TRANSMISSION 53

OUTPUT SHAFT ASSEMBLY

Replace the 2nd gear and synchro hub.

Using an appropriately sized tube refit the 1st gear

bearing sleeve.

Replace the 1st/2nd synchronizer assembly.

Replace the 1st gear needle bearings and spacer.

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54 SECTION 21 - TRANSMISSION

Replace the 1st gear.

Replace the 4 wheel drive gear using Loctite 649

spline lock or equivalent.

NOTE: the gear should be fitted with the fluted boss

against the 1st gear. (On 2WD models a spacer is fit-
ted in place of the gear).

Using an appropriately sized tube refit the rear bear-

ing.

Invert the shaft and refit the 3rd gear, synchro hub
and circlip.
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SECTION 21 - TRANSMISSION 55

Refit the 3rd/4th synchronizer assembly.

Refit the 4th gear and thrust washer as shown.

Using an appropriately sized tube replace the front

bearing.
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56 SECTION 21 - TRANSMISSION

HYDRAULIC DOG CLUTCH 4 WHEEL DRIVE

DISASSEMBLY
The hydraulic dog clutch 4 wheel drive assembly.

Position the shaft in a soft jawed vice and remove

the sealing ring.

Using the appropriate bearing puller 380002685 re-

move the rear bearing.

Remove the thrust washer.

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SECTION 21 - TRANSMISSION 57

Remove the 4 wheel drive gear.

Remove the two needle bearings and spacer.

Invert the shaft and using the appropriate bearing

puller 380002685 remove the front bearing.

Using the appropriate tool 380002692 compress the

spring and release the circlip.
 Copyright ©

58 SECTION 21 - TRANSMISSION

Remove the circlip, retainer and spring.

Remove the piston drum assembly.

Remove the piston seal and O-ring from the shaft

and discard.

Remove and discard the piston seal and O-ring from

the piston drum.
 Copyright ©

SECTION 21 - TRANSMISSION 59

HYDRAULIC DOG CLUTCH 4 WHEEL DRIVE

ASSEMBLY
Fit a new O-ring and sealing ring to the shaft.

Fit a new O-ring and sealing ring into the piston.

Bend the sealing ring into a heart shape as shown to
assist assembly.

Lubricate the seals with a light grease and refit the

piston to the shaft.

Replace the piston spring and retainer.

 Copyright ©

60 SECTION 21 - TRANSMISSION

Using the appropriate tool 80002692 compress the

spring and retainer and refit the circlip.

Using an appropriately sized tube refit the front bear-

ing.

Invert the shaft and refit the two needle bearings and
spacer as shown.

Replace the 4 wheel drive gear.

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SECTION 21 - TRANSMISSION 61

Replace the thrust washer.

Using an appropriately sized tube replace the rear

bearing.

Fit a new sealing ring. (To avoid damage the sealing

ring should be left off until all shimming operations
have been completed).
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62 SECTION 21 - TRANSMISSION

PERMANENT 4 WHEEL DRIVE SHAFT

DISASSEMBLY
The permanent 4 wheel drive shaft.

Using the appropriate bearing puller 380002685 re-

move the front and rear bearings.

Remove the 4 wheel drive gear.

 Copyright ©

SECTION 21 - TRANSMISSION 63

PERMANENT 4 WHEEL DRIVE SHAFT ASSEMBLY

Replace the 4 wheel drive gear using Loctite 649, or
equivalent, on the shaft splines.
Then using a suitably sized tube refit the front and
rear bearings.
 Copyright ©

64 SECTION 21 - TRANSMISSION

HYDRAULIC MULTI PLATE CLUTCH 4 WHEEL

DRIVE SHAFT DISASSEMBLY
The hydraulic multiplate clutch 4WD shaft assembly.

Mount the shaft assembly in a suitable soft jawed

vice and remove the rear sealing ring.

Using the appropriate tool 380002685 remove the

rear bearing.

Remove the thrust washer and needle bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 65

Remove the 4WD gear.

Remove the needle bearings and spacer.

Remove the needle bearing and thrust washer.

Remove the clutch pack retaining clip.

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66 SECTION 21 - TRANSMISSION

Remove the clutch pack retaining plate.

Remove the clutch pack.

Using the appropriate tool 380002690 compress the

piston return spring and release the circlip.

Remove the clip retainer and spring.

 Copyright ©

SECTION 21 - TRANSMISSION 67

Remove the piston from the drum.

Remove and discard the piston sealing rings.

Invert the shaft and remove the front bearing using

the appropriate tool 380002685.
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68 SECTION 21 - TRANSMISSION

HYDRAULIC MULTI PLATE CLUTCH 4 WHEEL

DRIVE SHAFT ASSEMBLY
Using an appropriately sized tube refit the front bear-
ing.

Re-new the piston sealing rings to assist assembly

the seals may be warmed in lukewarm water prior to
assembly.

NOTE: the outer seal must be fitted with the open

edge facing away from the clutch pack.

Using the appropriate tool 380002684 compress the

piston sealing rings. The seals should be left in the
tool 380002684 for a minimum of 30 minutes prior to
assembly into the clutch drum.

Lubricate the seals with a light grease and refit the

piston into the clutch drum. Then replace the spring,
retainer and circlip.
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SECTION 21 - TRANSMISSION 69

Using the appropriate tool 380002690 compress the

piston return spring and locate the circlip into its
groove.

Replace an externally splined (plain) disc then an in-

ternally splined (friction) disc alternately until 8 plain
discs and 8 friction discs have been fitted.

Replace the retaining plate and fit a new retaining

clip.

Refit the thrust washer and needle bearing.

 Copyright ©

70 SECTION 21 - TRANSMISSION

Refit the 4 wheel drive gear.

Refit the needle bearings and spacer.

Refit the needle bearing and thrust washer.

Using an appropriately sized tube refit the rear bear-

ing.
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SECTION 21 - TRANSMISSION 71

Refit a new sealing ring and lubricate with a light

grease. (To avoid damage the sealing ring should be
left off until all shimming operations have been com-
pleted).
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72 SECTION 21 - TRANSMISSION

THE OIL PUMP DISASSEMBLY AND ASSEMBLY

Individual components of the oil pump are non serv-
iceable. The pump may, however, be stripped for
cleaning and examination purposes.

View showing a dismantled pump assembly.

The pump oil seal may be replaced using an appro-

priately sized tube.
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SECTION 21 - TRANSMISSION 73

DIRECTION CONTROL VALVE DISASSEMBLY

AND ASSEMBLY
Disassembly of the control valve is not generally rec-
ommended as, with the exception of the solenoids,
individual parts are non serviceable. It may however
be dismantled for cleaning and examination.
The valve fitted may be either the modulated type or
the non-modulated type.

The retaining nut, coil and washer removed.

The modulation components removed.

There are 4 O-rings fitted to the underside of the

valve which may be renewed if necessary.
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74 SECTION 21 - TRANSMISSION

GEAR LEVER HOUSING DISASSEMBLY AND

ASSEMBLY
Remove the plastic ties from the rubber gaiter and
pull the assembly apart.

Before re-assembly remove all traces of old sealant

from the joint faces.

Apply a bead of RTV joint compound (Loctite 5900)

to the sealing face.

Lubricate the ball seating with a light grease and

push the two halves of the assembly together. Se-
cure the rubber boot with two new plastic ties.
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SECTION 21 - TRANSMISSION 75

TRANSMISSION ASSEMBLY
All nylon patch bolts may be re-used 5 to 6 times pro-
vided a prevailing thread torque of 20 to 25 Nm is re-
corded.
All shafts and bearings should be lubricated with
transmission fluid prior to assembly.
To prevent possible contamination of hydraulic parts
lint or cotton rags should not be used.

Position the front case as shown and using a suita-

bly sized tube fit a new 4 wheel drive output shaft oil
seal to a depth of 6 mm below the housing face. Fill
the seal lip with light grease. (Not fitted on 2WD
model).

If previously removed, replace the two plug and O-

ring assemblies and tighten to a torque of 41-54 Nm.

Refit the oil pump assembly and sealing ring. Tight-

en 4 bolts to a torque of 18-31 Nm.
New copper washers must be fitted under the bolt
heads. Finally check for free rotation of pump rotor.
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76 SECTION 21 - TRANSMISSION

Invert the case and then refit the bearing cups if pre-
viously removed.

Using a suitable tool push the inner detent spring

and ball into the case and secure in place with a
dummy plug as shown.

Dummy plug in place.

Replace the countershaft and reverse idler shaft as-

semblies.
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SECTION 21 - TRANSMISSION 77

Slide the 1st/2nd fork onto the 3rd/4th rail then refit
the 3rd/4th shift fork and tighten the screw to a
torque of 18-25 Nm. Hold the forks and rail in place
on the output shaft then refit the complete assembly
into the case. The shift rail should displace the dum-
my plug as it enters the bore.

NOTE: check that the inner detent spring and ball

have not become displaced and remove the loose
dummy plug from the case sump.

Push the interlock ball into the detent bore.

Refit the 1st/2nd shift rail and tighten the shift fork
screw to a torque of 13-18 Nm.
Check that the interlock ball is correctly positioned in
between the two rails.

Replace the outer detent ball and spring.

Tighten the plug to a torque of 41-54 Nm.
 Copyright ©

78 SECTION 21 - TRANSMISSION

Replace the 4 wheel drive shaft assembly.

(Not fitted on 2 wheel drive models).
Lubricate the rear seal with a light grease.

Lubricate the input shaft front and rear seals with a

light grease and refit the shaft assembly into the
case.

Rear case with all shaft assemblies fitted.

Position the rear case as shown and using a suitably

sized tube fit a new output shaft oil seal to a depth of
6 mm below the housing face. Fill the seal lip with a
light grease.
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SECTION 21 - TRANSMISSION 79

Invert the case and replace the shim packs and

bearing cups. The 2 mm thick spacer shim should be
fitted into the case first, then fit the remaining shims
followed by the bearing cup.
A light grease may be used to help hold the cups in
the case.

Refit the rear case, (without sealant at this stage),

and secure with at least 6 equally spaced bolts.
When fitting the rear case be careful to avoid dam-
aging the input shaft sealing rings.

Position a D.T.I. on the end of the input shaft as

shown, and using a suitable pry bar through the side
access hole, measure and note the shaft end float.

NOTE: all shaft assemblies should be rotated sever-

al times to seat the bearings prior to measuring the
end float.

Attach a suitable shimming tool 380002693, to the

end of the reverse idler shaft. Position a D.T.I. as
shown, and using a pry bar lift the shaft, then meas-
ure and note the end float.
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80 SECTION 21 - TRANSMISSION

Attach a suitable shimming tool 380002693, to the

end of the countershaft.
Position a D.T.I. as shown, and using a pry bar lift
the shaft, then measure and note the end float.

Attach a suitable shimming tool 380002693, to the

end of the output shaft. Position a D.T.I. as shown,
and using a pry bar lift the shaft, then measure and
note the end float.

Attach a suitable shimming tool 380002693, to the

end of the 4 wheel drive shaft. Position a D.T.I. as
shown, and using a pry bar lift the shaft, then meas-
ure and note the end float.
Not fitted on 2 wheel drive model.

Remove the rear case and add or remove shims as

necessary to give 0.025 to 0.076 mm end float on all
shafts.

Repeat steps 17 to 22 until all shaft end floats are

correct.

Replace the 4 O-rings in the front case. (There are

only 3 fitted on the 2 wheel drive model).

NOTE: the input shaft and 4WD shaft sealing rings

should now be fitted.
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SECTION 21 - TRANSMISSION 81

Refit the rear case using an approved liquid gasket

(Loctite 5203) taking care not to damage the input
shaft or 4WD shaft sealing rings. Tighten the 17
bolts to a torque of 45-64 Nm.

Replace the shaft end plug and O-ring assemblies.

Note the special breather plug is fitted in the reverse
idler position. Tighten to a torque of 41-54 Nm.

Fit a new expansion plug to the shimming access

hole using an approved sealant. (Loctite 649).

Replace the output yoke, O-ring, washer and bolt.

Then tighten to a torque of 68-88 Nm.
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82 SECTION 21 - TRANSMISSION

Replace the spacer, 4WD yoke, O-ring, washer and

bolt. Then tighten to a torque of 68-88 Nm.

Refit the cold start ball, spring and housing.

Then tighten to a torque of 46-60 Nm.

Lubricate the seals with transmission fluid then refit

the pressure regulator valve and tighten to a torque
of 46-60 Nm.

Lubricate the seals with transmission fluid then refit

the converter regulator valve and tighten to a torque
of 23-30 Nm.
 Copyright ©

SECTION 21 - TRANSMISSION 83

Refit the temperature sender and tighten to a torque

of 20-27 Nm.

Ensure the 4 O-rings are in place then refit the con-

trol valve assembly, tighten the 4 cap screws to a
torque of 6.8 to 8.5 Nm. Refit the 4 plastic caps to the
capscrew holes.

NOTE: the valve can only be fitted one way round as

it is located by a small dowel pin.

Refit the strainer, spacer, O-ring and cover plate.

Then tighten the two screws to a torque of 18-31
Nm.

Refit the drain plug and O-ring assembly.

Tighten to a torque of 34-54 Nm.
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84 SECTION 21 - TRANSMISSION

Refit the 4th gear lock out screw, (when this feature
is not required a shorter blanking screw is fitted). On
some applications an additional sealing plug may be
fitted.

Apply a bead of RTV joint compound (Loctite 5900)

to the gear case.

Refit the gear lever assembly and tighten the three

bolts to a torque of 16-24 Nm.

Refit the filter housing and gasket. Tighten the two

bolts to a torque of 45-64 Nm.

NOTE: do not use sealant on this gasket as it is

graphite coated.
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SECTION 21 - TRANSMISSION 85

Lubricate the seal with a light grease and screw on

a new oil filter. Tighten to a torque of 7 to 10 Nm, or
a half to three quarters of a turn after initial seal con-
tact.

Lubricate the seals with a light grease and refit the 4

wheel drive solenoid spool.
Tighten to a torque of 20-27 Nm. (Not fitted on
2WD).

Refit the 4 wheel drive solenoid coil and nut. Tighten

to a torque of 5.4 Nm maximum. (Not fitted on 2WD).

If previously removed refit the 4 wheel drive clutch

supply pipe, apply sealant (Loctite 542) to threads
and tighten nuts to a torque of 6.8-10.2 Nm. (Not fit-
ted on 2WD).
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86 SECTION 21 - TRANSMISSION

TEST PORT
The transmission oil, should be at an approximate
temperature of 80 °C during pressure tests.
All pressure test ports have a 9/16” UNF thread.
Forward, reverse and 4WD clutch pack pressures
should not be more than 1 bar lower than the oil
pump pressure.

Oil pump pressure test port. Pressure should be

13.5 to 15.5 bar at maximum engine speed. (Ap-
proximately 2500 rpm).

Reverse clutch pressure test point.

Pressure should be 12.5 to 15.5 bar at maximum en-
gine speed. (Approximately 2500 rpm).

Forward clutch pressure test point.

Pressure should be 12.5 to 15.5 bar at maximum en-
gine speed. (Approximately 2500 rpm).
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SECTION 21 - TRANSMISSION 87

Four wheel drive pressure test point.

Pressure should be 12.5 to 15.5 bar at maximum en-
gine speed. (Approximately 2500 rpm).

Converter relief pressure test point.

Pressure should not exceed 7.5 bar at maximum en-
gine speed. (Approximately 2500 rpm).
For Coaxial transmissions max pressure should be
10.5 bar.

Lubrication pressure test point. Pressure should be

0.5 to 2.5 bar at maximum engine speed. (Approxi-
mately 2500 rpm).
If a malfunction of the transmission is indicated a
systematic pressure checking procedure should be
followed. These checks should be carried out while
the transmission is still in the vehicle so that true op-
erating conditions are created. Pressure checks are
essential since a failure in the hydraulic system may
not be easily traceable when the transmission is
stripped down on a bench.
All pressure checks should be carried out with the
transmission gear lever in the neutral position, the oil
temperature at 80 to 85 °C, and the engine speed
maintained at 2000 to 2500 rpm. As a safety precau-
tion the vehicles parking brake should be applied.
All pressure test ports have a 9/16” UNF thread. A
pressure gauge is required that will measure up to
20 bar.
For test port locations refer to illustrations at page
18.
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88 SECTION 21 - TRANSMISSION

PARKING BRAKE
The caliper assembly is mounted directly onto the
rear face of the transmission housing.

1. Mounting face
2. Locknut
3. Mounting bolt
4. Outer locknut
1 2 A
A. Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm gap between the locknut
and sleeve.
Then torque locknuts against mounting surface
to 155 Nm.
B. Adjust this nut until pads are in contact with the
brake pads.
Then loosen 1/2 turn.
Finally torque outer locknut to 60-70 Nm.

B 4

F27714

IMPORTANT:
BRAKE PAD: the minimum acceptable thickness of
the brake pads is 2.286 mm.
BRAKE DISK: the nominal thickness of the disk is
9.5 mm.
The maximum total wear limit for the disk is 1.524
mm.
Based on the nominal thickness of 9.5 mm this
would give a minimum thickness of 7.976 mm.
 Copyright ©

SECTION 21 - TRANSMISSION 89

Brake pad replacement

Remove the retaining spring clip.

Withdraw the friction pads.


90
1.12 FAULT FINDING
FAULT
Transmission fails to drive in
either direction
Transmission drives in one
direction only
Delay in taking up drive
No drive from 4WD
Transmission overheating
Operating in too high of gear
range for conditions
Difficult gear selection
Vehicle moves with direction
valve in neutral position
High stall speed
Low stall speed
Copyright ©
SECTION 21 - TRANSMISSION
CAUSE
Low or no pump pressure.
Low or no oil in transmission.
Mechanical failure in transmission.
Worn or broken input shaft sealing rings.
Pressure regulator valve faulty.
Direction control valve not operating.
Blockage in oil ports restricting flow.
Low oil pressure on one clutch pack due to leaks.
Clutch piston seals worn or damaged.
Clutch pack excessively worn.
Direction valve or coil faulty.
Mechanical failure in transmission.
Blockage in oil ports restricting flow.
Worn or damaged input shaft sealing ring.
Low converter pressure.
Low oil level.
Low clutch pressure.
Faulty modulation in direction control valve.
Blockage in direction valve.
Blockage in oil ports restricting flow.
4WD solenoid valve or coil not operating.
Mechanical failure in transmission.
Low 4WD clutch pack pressure.
4WD clutch pack worn.
Oil level too high or low.
Restriction in cooler flow.
Low oil pressure.
Clutch packs slipping due to low pressure or wear.
Mechanical failure in transmission.
Excessive stall operation.
Shift to lower gear.
Forward or reverse clutch pack pressurized when not selected.
Direction valve faulty.
Input shaft sealing rings leaking.
Mechanical failure in transmission.
Forward or reverse clutch pack not releasing due to mechanical failure.
See “Difficult gear selection”.
Low oil level. Air in oil.
Clutch plates slipping due to low pressure or wear.
Torque converter faulty.
Converter relief valve faulty.
Incorrect torque converter fitted.
Poor engine performance.
Torque converter defective.
Incorrect torque converter fitted.

Low Pump Pressure
High pump pressure
Low forward or reverse clutch
pack pressure
High forward/reverse clutch
pack pressure
Converter pressure low
Converter pressure high
Low 4WD clutch pack
pressure
High 4WD clutch pack
pressure
Low lubrication pressure
Copyright ©
SECTION 21 - TRANSMISSION 91
Worn or broken pump.
Leaking pump sealing ring.
Blocked oil strainer or filter.
Blockage in oil ports between transmission sump and oil pump.
Pressure regulator valve stuck open.
Cold start valve stuck open.
Pressure regulator valve faulty.
Has normal operating oil temperature been reached?
Faulty direction control valve.
Piston seal or O-ring leaking.
Input shaft sealing ring leaking.
Pressure regulator valve faulty.
Converter relief valve faulty.
Leak in converter, oil cooler or connecting hoses.
Very hot oil.
Converter relief valve faulty.
Blockage or restriction in oil cooler.
Very cold oil.
4WD piston seals leaking.
4WD shaft sealing ring leaking.
Leak from 4WD clutch supply pipe.
Faulty 4WD solenoid.
Blockage or restriction in 4WD clutch supply pipe.
Pressure regulator valve faulty.
Blockage or restriction in oil cooler.
Input shaft front sealing ring leaking.
Very hot oil.
 Copyright ©

92 SECTION 21 - TRANSMISSION

FAULT DIAGNOSIS MECHANICAL SYSTEM

FAULT CAUSE
Noise Vehicle driveline problem:
Axles, propshafts, engine, engine mounts.
Misalignment of transmission/engine.
Bearings worn or damaged.
Gear teeth damaged or broken.
Excessive end float of shafts or gears.
Clutch plate failure forward, reverse or 4WD.
Incorrect grade of oil in transmission.
Low oil level.
Gear or thrust washer beginning to seize.
Difficult gear selection Shift rods worn or bent.
Shift forks worn, loose or twisted.
Synchronizer assemblies worn or damaged.
Clutch pack not releasing due to mechanical fault.
Clutch pack not releasing due to hydraulic fault.
Gear shift stub lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.
Jumping out of gear Detent springs worn or broken.
Synchronizer or gear dog teeth worn or damaged.
Synchronizer assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy.
not allowing gears to be fully selected.
Excess end float on output shaft assembly or gears.
 Copyright ©

SECTION 21 - TRANSMISSION 93

1.13 SPECIAL TOOLS

P/N CNH DESCRIPTION

380002683 Input and reverse idler shaft bearing removal collect
380002684 Piston seal sizing ring (hydraulic 4WD only)
380002685 4WD shaft front/rear and Coaxial input shaft front bearing removal collect
380002686 Output shaft front bearing removal collect
380002687 C/shaft and output shaft rear bearing removal collect
380002689 Input shaft spring compressor
380002690 4WD shaft spring compressor (hydraulic multiplate 4WD only)
380002691 C/shaft front bearing removal collect
380002692 Coaxial input shaft and hydraulic dog clutch 4WD shaft spring compressor
380002693 Shimming adapter
 Copyright ©

94 SECTION 21 - TRANSMISSION

2. POWERSHIFT TRANSMISSION “DANA T16000”

This transmission is used only on Powershift loader backhoes models 590 Super R and 695 Super R.

A B

1
F27718

2.1 TECHNICAL SPECIFICATIONS

HYDRAULIC SPECIFICATIONS
Suitable for operation from ambient to 120 °C continuous operating temperature.
Must withstand a 20 bar continuous pressure and a 40 bar variable pressure.
Conform SAE J1019 and SAE J517, 100RI.

Weight ...................................................................................................................................................... 290 kg

BOLT TORQUES
Output flanges............................................................................................................................... 339 - 407 Nm
Filter torque ....................................................................................................................................... 30 - 38 Nm
Control valve, connector nut to cover.................................................................................................... 6 - 8 Nm

ELECTRICAL SPECIFICATIONS
Solenoid (forward reverse, high/low, 2nd/1st, modulation, disconnect) coil resistance...........28 Ω ± 2 Ω at 20 °C
Electronic controlled modulation valve, coil resistance ...................................3.55 Ohm (± 0.25 Ohm) at 20 °C
Speed sensor:
- type ................................................................................. magneto resistive sensor with 7/14 mA current loop
- frequency ......................................................................................................................................0 - 25000 Hz
- sensing distance .............................................................................................................................. 0 - 2.5 mm
 Copyright ©

SECTION 21 - TRANSMISSION 95

2.2 TRANSMISSION CONTROLS

4X2 POWERSHIFT TRANSMISSION CONTROL

1. TRANSMISSION POWERSHIFT DIRECTION 4X2 POWERSHIFT TRANSMISSION

LEVER: four gears are selectable for the
required ground speed in forward and two gears
for reverse travel.
IMPORTANT: the gear changes and direction of
travel are governed by the micro processor to main-
tain smooth and safe changes, irrespective of gear
selected. Therefore upshifting, downshifting or di-
rection of travel through the gears will only occur
when the monitored machine speed is safe to do so.
The transmission fitted to this machine is designed
to powershift gear changes supplying drive to the
machine wheels depending upon the gear and di-
rection selected. The transmission is controlled by a
microprocessor in the Powershift lever unit (1).
6. The powershift lever (1) with electronic speed
selection actuates the powershift transmission
with four forward speeds, two reverse speeds.

2. DIFFERENTIAL LOCK SELECTION SWITCH:

depressing the spring loaded switch will lock
both rear wheels together giving equal drive and
will disengage when wheel torque equalises or
the foot brakes are applied.
3. LOADER ATTACHMENT CONTROL LEVER
4. TRANSMISSION DISCONNECT BUTTON
5. KICKDOWN SWITCH: if the machine is in 2nd
gear and 1st is required for loader work
engaging kickdown instantly drops the gear from
2nd to 1st. When reverse is selected the
transmission reverts to 2nd gear.
 Copyright ©

96 SECTION 21 - TRANSMISSION

4X2 POWERSHIFT TRANSMISSION DISPLAY (EGS) - FORWARD SELECTION

 Copyright ©

SECTION 21 - TRANSMISSION 97

4X2 POWERSHIFT TRANSMISSION DISPLAY (EGS) - REVERSE SELECTION

 Copyright ©

98 SECTION 21 - TRANSMISSION

Powershift Lever Display - (LEDs)

LEDs - Numbered 1 through 4:
Indicate the direction of travel by the colour of the
LED
Forward = Green
Neutral = Red
Reverse = Orange

and also indicate the selected shift lever gear.

STEADY ILLUMINATED LED: indicates selected

transmission gear.
FLASHING LED: indicates the actual transmission
gear engaged (if different from that selected).

LEDs - Numbered 1 through 8: used during test

modes

1 2 3 4 5 6 7 8

LED - Number 8: illuminates green when the ma-

chine is at a standstill (in normal mode).

1 2 3 4 5 6 7 8

LED - Letter T = Self-diagnostic Mode: T

Used in self-diagnostic test mode and will illuminate
during self test.

NOTE: in the event of a fault, (the light will flash),

Contact your Authorized Dealer for assistance.

LED - Letter N Indicates Neutral: N

Illuminates when the transmission is shifted to neutral.

Powershift Lever and Microprocessor Functions

The microprocessor controls the transmission and
self checks its own memory continuously to ensure
that gear selection and range changes are always
performed in a safe manner.
Should a fault occur in the transmission or the micro-
processor, the microprocessor will default to the re-
set mode.
 Copyright ©

SECTION 21 - TRANSMISSION 99

Reset Mode:
When the microprocessor defaults to reset mode
both the T and N LED’s are displayed simultaneously
to indicate that a reset has taken place.
If no critical faults are active the microprocessor se-
lects N2 and goes to the Neutral lock state. See
“Driving with Powershift” chapter.

Limp home:
If a fault is detected at power up the limp home facil-
ity is automatically selected.

IMPORTANT: if limp home is active, only 1st and

2nd gear will be selectable but without modulation.
Limp home active can be identified by the illumina-
tion of the following LEDs.
- Consult your Dealer.

T - LED N - LED CONDITION

Flashing ON Last fault currently shown on display
Flashing Flashes Slower Input error detected
Flashing Flashes in Phase Non critical output error detected
Flashing Flashes Faster Safety critical output error detected
 Copyright ©

100 SECTION 21 - TRANSMISSION

Selecting Neutral
At power up, “Neutral and 2nd Gear” are automati-
cally selected regardless of the Powershift lever po-
sition (1). The LED-2 and the N-LED are illuminated
RED, (neutral 2nd), the microprocessor is in a neu-
tral lock state.
If after driving, neutral is selected and the shift lever
stays in neutral for more than 3 seconds the micro-
processor automatically defaults to the neutral lock
state for safety. In neutral an automatic shift routine
takes effect to prevent damage to the transmission
due to overspeeding.

Leaving Neutral
A feature of the Powershift lever is the neutral lock
state, which does not allow forward or reverse direc-
tion drive to be selected. This feature prevents the
machine accidentally moving should the lever be
knocked into forward or reverse. To leave the neutral
lock state, you select drive direction followed by an
upshift by rotating the shift lever.

Selecting Forward
To select forward travel push the lever away from
you and the “F” LED will illuminate green.

NOTE: when forward is selected you will not be giv-

en any indication of gear selected, only the maxi-
mum selected gear the transmission will shift to. The
microprocessor is programmed to be an automatic
speed based shift system.
In addition whether forward actually engages at that
time, depends on the status of the machine, for ex-
ample if on the move, road speed and direction will
be considered before any shift changes take place.

Selecting Reverse
To select reverse travel pull the lever towards you
and the reverse “R” LED will illuminate orange.

NOTE: when reverse is selected you will not be giv-

en any indication of gear selected, only the maxi-
mum selected gear the transmission will shift to. The
microprocessor is programmed to be an automatic
speed based shift system.
In addition whether reverse actually engages at that
time, depends on the status of the machine, that is if
on the move road speed and direction will be consid-
ered by the microprocessor.
 Copyright ©

SECTION 21 - TRANSMISSION 101

Upshifting
Upshifting to a desired gear from neutral is achieved
by twisting the handgrip counter clockwise (+) in sin-
gle movements, If held in this position the processor
will advance the shift selection from 2 through to 4 in
1.8 sec intervals.

NOTE: an upshift request after a downshift is de-

layed for 2 seconds. Should an error occur with the
speed sensor the microprocessor will not allow up-
shifts above 2nd gear and will be indicated by the “T”
LED flashing and the “N” LED flashing slower.

NOTE: if climbing up a steep incline select 2nd and

proceed, if speed and power allow upshift into 3rd
and 4th.

Downshifting

SWARNING
If descending down a steep incline select 2nd and
proceed, upshifting only when safe to do so. You can
not downshift to reduce speed if the machine speed
is above 15 km/h.

Downshifting to the desired gear is achieved by

twisting the handgrip clockwise (-) in single move-
ments. If held in this position the processor will de-
crease the shift from 4, if the shift lever was in this
gear, through to 1 in 1.5 sec intervals.

NOTE: if the gear requested and the shift attainable

are not the same because of torque converter tur-
bine rpm being too high, the gear position LED (e.g.
LED 4) will flash and the shift lever position will illu-
minate, not flashing, (e.g. LED 2), until the requested
gear is reached. When a gear position LED is flash-
ing this indicates that the machine has to reduce
speed to reach the requested gear.
 Copyright ©

102 SECTION 21 - TRANSMISSION

Direction Changes
Changing driving direction is achieved simply by
shuttling the Powershift lever between forward and
reverse and vice versa which is allowed at any time.
The system response however depends on machine
speed and currently engaged gear. When driving in
1st or 2nd gear direction changes are unrestricted
and are granted immediately.

F1 - R1 F2 - R2
R1 - F1 R2 - F2

When driving forward in 3rd or 4th gear two respons-

es are possible depending on machine speed.

RESPONSE 1: If the machine speed in forward is

above 15 km/h and reverse is selected downshift en-
gages but momentum forward remains, until the
speed lowers sufficiently to allow downshift to take
place when reverse is achieved in 2nd gear.

RESPONSE 2: If the machine speed in forward is

less than 15 km/h reverse takes place immediately
into 2nd gear.

Should a speed sensor fault be detected while in F3

or F4 a downshift sequence to 2nd gear will take
place and is indicated by the LED “T” flashing fast
and the LED “N” flashing slowly.

NOTE: if the transmission is in forward 1st gear due

to kick down the direction change will result in selec-
tion of reverse 2nd gear for efficient pull away. Refer
to Kick down for more information.
 Copyright ©

SECTION 21 - TRANSMISSION 103

Transmission Powershift
In the previous paragraphs shift changes have been
shown as precise movements and twist actions of
the Powershift lever. However the transmission can
change gear automatically in forward or reverse as
described in the following paragraph:
Select forward and 4th gear on the Powershift lever
and with the handbrake released apply pressure to
the foot accelerator. As the engine revs and machine
speed increase the transmission will start from 2nd
gear and change up through 3rd and 4th gears up to
maximum road speed.
When you require to slow down or stop release the
foot accelerator and apply the foot brake, the trans-
mission will automatically downshift through 4th, 3rd
and 2nd gear as the machine speed decreases.
Once stopped apply the handbrake and neutral will
be selected by the microprocessor.
To select drive again, simply twist the handgrip to se-
lect 4th and with the handbrake released apply pres-
sure to the foot accelerator.

Kick Down
The kick down facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels.
This is achieved by the instant gear change from 2nd
to 1st by the use of the button (1) without the need to
use the twist grip on the Powershift lever.

NOTE: the kick down facility is only available when

the transmission is in 2nd gear and the kick down
button (1) is depressed. If kick down can not be
achieved (machine speed too high) the LED 1 will be
illuminated and LED 2 will be flashing.

Transmission Disconnect
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and you
have sufficient dirt in the bucket press the disconnect
switch which disengages the transmission and al-
lows the full power of the engine to be directed to the
hydraulic oil pump.
Disconnect is available in 1st and 2nd gear.

NOTE: transmission disconnect is selectable, when

the machine speed is less than 5 km/h and by de-
pressing the button on the loader lever and remains
active until the pedals or switch are released.
 Copyright ©

104 SECTION 21 - TRANSMISSION

Speed Ranges
The microprocessor controlling the Powershift trans-
mission is pre-programmed to control the speed at
which the gear changes take place.
This effectively protects the transmission from ex-
cess forces, should gear changes be selected at
higher speeds than is desirable.

(Except 695 Super R) shown in the chart opposite

with an 18.4 X 26 R4 tyre fitted is the approximate
(within 10%) maximum speed available and at which
speed an automatic shift takes place in each gear.
(...) = Automatic upshift speed
[...] = Automatic downshift speed
As can be seen when down shifting from 4th gear at
maximum speed 39.5 km/h the microprocessor will
not allow the down shift to take place until the speed
has dropped to approximately 19.9 km/h.
Refer to the chart for complete upshift and downshift
speed change details.

NOTE: in some countries the road speed of 40 km/h

is not allowed. In these circumstances the transmis-
sion is governed to a maximum of 30 km/h and the
shift speed range reduces accordingly.
 Copyright ©

SECTION 21 - TRANSMISSION 105

2.3 LUBRICATION

Oil capacity................................................ 14 litres

Suggested oil .......... Axcela Trans XHD MAT3525

Daily
Check oil level daily with engine running at idle (600
rpm) and oil at 82 - 93 °C.
Maintain oil level at full mark.

Normal drain period

Normal drain period and oil filter change are for av-
erage environment and duty cycle condition.
Severe or sustained high operating temperature or
very dusty atmospheric conditions will cause accel- 2 1
erated deterioration and contamination.
F27717
For extreme conditions judgement must be used to
determine the required change intervals. 1. Drain plug
Z Every 1000 hours change oil filter. 2. Oil level plug
Z Every 1000 hours drain and refill system as follows:
drain with oil at 65 - 93°C.
- Drain transmission.
- Oil filter, remove and discard, install new filter.
- Refill transmission (14 litres).
- Run engine at idle (600 rpm) to prime converter
and lines.
- When oil temperature is at 82 - 93 °C adjust oil level
to full mark.

NOTE: it is recommended that oil filter be changed

after 100 hours of operation on new, rebuilt or re-
paired unit.
 Copyright ©

106 SECTION 21 - TRANSMISSION

2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS

Normal operating temperature 70 - 120 °C
measured at temperature check port to cooler.
Maximum allowed transmission temperature 120
°C.
Transmission regulator pressure (*) - (neutral 2nd
speed).
Z at 600 rpm: 16.5 bar.
Z at 2200 rpm: 19.6 - 23.1 bar.
Pump flow (*)
Z at 2200 rpm in neutral 2nd speed: 64.9 l/min
minimum.
Z at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd
maximum 3 l/min less than in neutral 2nd.
Z at 2200 rpm in forward 3rd and 4th: maximum
5l/min less than in neutral 2nd.
Clutch pressures (*) at 2200 rpm:
Z 18.1 - 21.5 bar clutch activated.
Z 0 - 0.2 bar clutch released.
Filter by-pass valve set at 4.1 - 5 bar (*).
Lube pressure (*) 0.3 - 0.5 bar at 47 l/min pump flow
(±1800 rpm).
Internal leakage (*) 1.5 - 3.0 l/min for each clutch.
Maximum total leakage 6.8 l/min (1.8 GPM) (clutch
leakage + range + converter leak + valve leak) with-
out disconnect clutch.
Safety valve: cracking pressure (*) 9,5 - 10,5 bar
To cooler (converter out) pressure (*) 2 bar mini-
mum at 2000 rpm and maximum 5 bar at no load
governed speed.
Converter by-pass valve set at 5 - 7 bar (*).
(*) All pressures and flows to be measured with oil
temperature of 82 - 93 °C.

A B

1
F27718

A. Front view 6. Pressure check port reverse clutch (reverse 1st

B. Rear view and reverse 2nd) 18.1-21.5 bar
7. Pressure check port 1st clutch (forward 1st, for-
1. Dipstick hole M27 x 2.5 ward 3rd, reverse 1st) 18.1-21.5 bar
2. Pressure check port forward hi clutch (forward 8. From cooler
3rd and forward 4th) 18.1-21.5 bar
3. Pressure check port from cooler (lube pressure)
4. Pressure check port forward port forward low
clutch (forward 1st and forward 2nd)
5. To cooler 18.1-21.5 bar
 Copyright ©

SECTION 21 - TRANSMISSION 107

C D

13 14

11
10

12

F27719

C. Left side view 11. To cooler

D. Top view
9. Pressure check port converter in 5-11 bar
10. Pressure check port 2nd clutch (forward 2nd -
forward 4th - reverse 2nd) 18.1-21.5 bar
12. Pressure check port 4WD 18.9-27.5 bar
13. Pressure check port regulator pressure 19.6-
23.7 bar
14. Filter plug M22 x 1.5

E F

15

16

17

F27720

E. Bottom view 16. Pressure check port converter out to cooler

F. Right side view 1.0625-12 UN2B SAE
17. Pressure before filter
15. Temperature check port converter out to cooler
M10 x 1
 Copyright ©

108 SECTION 21 - TRANSMISSION

2.5 TRANSMISSION COOLER

F27721

1. To cooler from converter

2. Transmission cooler
3. From cooler to transmission lube distributor

COOLER LINES SPECIFICATIONS

Suitable for operation from ambient to 120 °C con-
tinuous operating temperature.
Must withstand a 20 bar continuous pressure and a
40 bar variable pressure.
Confirm SAE J1019 and SAE J517, 100RI
 Copyright ©

SECTION 21 - TRANSMISSION 109

2.6 TRANSMISSION HYDRAULIC DIAGRAM

1
5
2 3

34 32 AA 33
bar 4 bar °C bar

7
71
°C

6
9
8
23 24 25 26 27 28

10 17
31
bar

20
11 12
35 18
bar
19 46
bar
45
bar
44
bar
42
bar
41
bar
47
bar

13

14 21 29 30 31 32 33 34
15

22
16

F27722

X
bar
Pressure check port
X
°C
Temperature check port

1. Operator compartment 18. Accumulator

2. Pressure gauge 19. Pressure booster 0 - 5.5 to 0 - 20 bar
3. Temperature gauge 20. Electronic controlled modulation valve 5.5 to 0
4. Torque converter bar
5. Torque converter (pressure difference 4 bar) by- 21. Modulated pressure 0 to 20 bar
pass valve 22. Clutch pressure 20 bar
6. Cooler 23. Solenoid N/forward
7. Lubrication 24. Solenoid N/reverse
8. Safety valve 10 bar cracking pressure 25. Solenoid high/low
9. Solenoid pressure 5 bar 26. Solenoid 2nd/1st
10. Pressure regulator valve 20 bar 27. Solenoid range modulation
11. By-pass valve pressure difference 4.3 bar 28. Solenoid disconnect
12. Filter 29. Reverse clutch
13. Pump 30. Forward low clutch
14. Air breather 31. Forward high clutch
15. Filter 32. 2nd clutch
16. Oil sump 33. 1st clutch
17. Pressure reducer to 5.5 bar 34. Disconnect clutch
 Copyright ©

110 SECTION 21 - TRANSMISSION

2.7 OPERATION

The transmission and hydraulic torque converter of the power train enacts an important role in transmitting en-
gine power to the driving wheels. In order to properly maintain and service these units it is important to first
understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
With the engine running, the transmission charging pump draws oil through the oil suction filter and directs it
through the oil filter and pressure regulating valve.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than 4.3
bar.
The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar.
Excess oil volume is bled off into the converter circuit. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this line becomes higher than 10 bar.
After entering the converter the oil is directed through the converter blade cavity and exits in the passage be-
tween the turbine shaft and pump drive shaft and flows to the cooler.
After leaving the cooler the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches.
The oil then gravity drains back to the transmission sump.
Across the converter and oil cooler is a converter by-pass valve which will open if the pressure difference is
higher than 4 bar (during start up from cold or at high rpm).
 Copyright ©

SECTION 21 - TRANSMISSION 111

Basically the transmission is composed of five main assemblies:

F27723

The converter and pump drive section

The input or directional clutches
The range clutches
The output section
Transmission control
 Copyright ©

112 SECTION 21 - TRANSMISSION

THE CONVERTER AND PUMP DRIVE SECTION

Engine power is transmitted from the engine fly-
wheel to the impeller through the impeller cover.
This element is the pump portion of the torque con-
verter and is the primary component which starts the
oil flowing to the other components which results in
torque multiplication. This element can be compared
to a centrifugal pump in that it picks up fluid at its
centre discharges at its outer diameter.
The torque converter turbine is mounted and dis-
charge opposite the impeller and is connected to the
turbine shaft or directional clutch shaft.
This element receives fluid at its outer diameter and
discharges at its centre.
The stator of the torque converter is located be-
tween and at the centre of the inner diameters of the
impeller and turbine elements. Its function is to take
the fluid which is exhausting from the inner portion of
the turbine and change its direction to allow correct
entry for recirculation into the impeller element.
This recirculation causes the converter to multiply F27724

torque. The converter and pump drive section

The converter will multiply engine torque to its de-
signed maximum multiplication ratio when the tur-
bine shaft is at zero rpm (stall).
Therefore we can say that as the turbine shaft is de-
creasing in speed, the torque multiplication is in-
creasing.
In the impeller cover a splined shaft is fitted which
runs inside and through the turbine shaft to drive a
hydraulic pump which is fitted at the back of the
transmission.
Since the shaft is connected to the centre of the im-
peller cover, the pump speed will be the same as en-
gine speed.
The rear side of the impeller cover has a tanged drive
which drives the transmission charging pump locat-
ed in the converter housing. The transmission charg-
ing pump speed is also the same as the engine
speed.
 Copyright ©

SECTION 21 - TRANSMISSION 113

THE INPUT OR DIRECTIONAL CLUTCHES

The turbine shaft driven from the turbine transmits
power to the forward or reverse clutches.
These clutches consists of a drum with splines and
a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings.
A steel disc with external splines is inserted into the
drum and rests against the piston.
Next, a friction disc with splines at the inner diameter
is inserted.
Discs are alternated until the required total is
achieved.
A back up plate is then inserted and secured with a
snap ring.
A hub with outer diameter splines is inserted into the
splines of discs with teeth on the inner diameter.
The discs and hub are free to increase in speed or
rotate in the opposite direction as long as no pres-
sure is present in that specific clutch.
To engage the clutch, the control valve which is fitted
on the side of the transmission will direct oil under F27725

pressure through tubes and passages to the select- The input or directional clutches
ed clutch shafts.
Oil seals are located on the clutch shafts.
These rings direct the oil through a drilled passage
in the shaft to the desired clutch.
Pressure of the oil forces the piston and discs
against the back up plate.
The discs with splines on the outer diameter clamp-
ing against discs with teeth on the inner diameter en-
ables the drum and hub to be locked together and
allows them to drive as one unit.
When the clutch is released, a return spring will push
the piston back and oil will drain back via the control
valve into the transmission sump.
The T16000 transmission has one reverse clutch
and two forward clutches (forward low and forward
high).
This in combination with the two range clutches re-
sult in the transmission having 4 forward speeds and
2 reverse speeds.
The engagement of the directional clutches is modu-
lated; which means that clutch pressure is built up
gradually.
This will enable the unit to make forward, reverse
shifts while the vehicle is still moving and will allow
smooth engagement of drive.
The modulation is controlled electronically in the
control valve.
 Copyright ©

114 SECTION 21 - TRANSMISSION

THE RANGE CLUTCHES

Once a directional clutch is engaged power is trans-
mitted to the range clutches (1st or 2nd).
Operation and actuation of the range clutches is
similar as the directional clutches.
The engagement of the range clutches is also mod-
ulated to enable a smooth engagement.
The modulation for these clutches is achieved by
means of a restrictor valve fitted in the control valve
which is controlled electronically and which limits oil
flow to the clutch during shifts.
In the clutch itself the plate before the end plates is
dished to build up the clamping force of the clutch
gradually.

F27726

The range clutches

THE OUTPUT SECTION

With a range clutch engaged power is finally trans-
mitted to the output shafts.
The transmission can have an upper output or lower
output at the rear side of the unit, and a lower output
at the front side. Output rotation of the rear upper
output is opposite the engine rotation when the for-
ward clutch is engaged, while output rotation of the
lower rear output and the front output is the same as
the engine rotation with the forward clutch engaged.
Ratio between upper and lower output is 0.951:1.
The lower front output has an axle disconnect clutch
to enable 4 wheel drive.
The clutch is similar as the other clutches except that
it has no modulation.
The disconnect is controlled electronically. Without
an electrical signal the clutch is always engaged.

F27727

The output section

 Copyright ©

SECTION 21 - TRANSMISSION 115

THE TRANSMISSION CONTROLS

The transmission is controlled by an electronic gear
selector (EGS). This unit has a microprocessor
which receives certain inputs (gear selector position,
speed sensor...) which are processed and will give
output signals to the control valve.
The control valve has 6 solenoid, 6 shift spools, a
pressure reducer, an electronic controlled modula-
tion valve, an accumulator, a pressure booster and
a speed sensor.
Operation of the valve is as follows:
Regulated pressure 20 bar is directed to the shift
spools, pressure booster and pressure reducer.
In the pressure reducer, regulated pressure is re-
duced to 5,5 bar. This reduced pressure is used as
supply for the solenoid and electronic controlled
modulation valve.
When activated, the electronic controlled modulation
valve will give an output pressure curve from 0 to 5
bar.
This pressure curve is multiplied in the booster so F27728

that a curve from 0 to 20 bar is available for the di- The transmission controls
rectional clutches.
Between the electronic modulation valve and the
booster is an accumulator to damper any hydraulic
vibration.
When forward is selected the electronic modulation
valve and the forward solenoid are activated.
The pilot pressure of the forward solenoid will move
the shift spool so that a forward clutch can be fed
with modulated pressure.
If the high/low solenoid is not activated the forward
high clutch is engaged, if it is activated the forward
low clutch is engaged.
When reverse is selected the electronic modulation
valve and the reverse solenoid are activated, the pi-
lot pressure of the reverse solenoid will move the
shift spool so that the reverse clutch can be fed with
modulated pressure.
The shift spools from forward and reverse are locat-
ed against each other with a return spring in be-
tween; this is to make sure that only one direction
can be selected.
Range is selected as follows:
if the range solenoid (2nd/1st) is not activated, regu-
lated pressure is fed through the modulation shift
spool and through the 2nd/1st shift spool to the 2nd
clutch.
If the range solenoid (2nd/1st) is activated, the pilot
pressure will move the shift spool so that 1st clutch
is fed.
The range clutches also have modulation which op-
erates as follows:
When the range is changed, oil will flow through the
modulation shift spool to the chosen range clutch
momentary until the friction discs are closed against
the dished plate. At that moment the range modula-
tion solenoid is activated.
 Copyright ©

116 SECTION 21 - TRANSMISSION

The pilot pressure will move the modulation shift

spool so that oil supply is fed through a restrictor
which is in by-pass of the valve.
The controlled volume of oil is used to push in the
dished outer plate gradually until the clutch is fully
closed.
This will give a smooth build up of torque. At that mo-
ment the range modulation solenoid is released, so
that the modulation shift spool return to its rest posi-
tion and allowing full oil flow to the clutch.
The control valve also controls the front lower output
disconnect clutch. If the solenoid is not activated full
oil pressure is fed through the disconnect shift spool
to the disconnect clutch.
If the solenoid is activated, pilot pressure will move
the disconnect shift spool to block oil supply to the
disconnect clutch to release it.
The control valve also has a speed sensor. This sen-
sor will pick up upper output gear speed.
This information is used in the electronic gear selec-
tor to determine shift logic.
Since the sensor picks up upper output gear speed,
the signal will be in direct relation of the turbine
speed if any directional clutch is engaged.

Transmission gear Activated solenoids Activated clutches

Forward 4 Forward Forward high, 2nd
Forward 3 Forward, 2nd/1st Forward high, 1st
Forward 2 Forward, Forward high/low Forward low, 2nd
Forward 1 Forward, Forward high/low, 2nd/1st Forward low, 1st

Reverse 1 Reverse, 2nd/1st Reverse, 1st

Reverse 2 Reverse Reverse, 2nd

Disconnect off Disconnect ---------------

Disconnect on --------------- Disconnect
 Copyright ©

SECTION 21 - TRANSMISSION 117

2.8 POWER FLOWS

F27729 F27730

1st speed forward 2nd speed forward

F27731 F27132

3rd speed forward 4th speed forward

 Copyright ©

118 SECTION 21 - TRANSMISSION

F27733 F27734

1st speed reverse 2nd speed reverse

 Copyright ©

SECTION 21 - TRANSMISSION 119

OPERATING VALVES AND SOLENOIDS

F29986

1. Transmission sump 14. 1st gear clutch

2. Transmission breather 15. Accumulator
3. Suction strainer 16. Electronic modulation valve 0-5.5 bar
4. Gerotor oil pump 17. Pressure reducing valve 5.5 bar
5. Pressure oil filter 18. 2nd / 1st shift spool
6. Filter by-pass valve 4.3 bar 19. Range modulation spool
7. System pressure regulating valve 20 bar 20. Range modulation restriction
Oil to converter circuit 21. Four wheel drive shift spool
8. Neutral reverse shift spool 22. Four wheel drive solenoid
9. Pressure booster 0-20 bar 23. Range modulation solenoid
10. Neutral forward solenoid 24. 2nd / 1st Solenoid
11. High / low shift spool
12. High / low solenoid
13. Neutral reverse solenoid
 Copyright ©

120 SECTION 21 - TRANSMISSION

TORQUE CONVERTER AND COOLER CIRCUIT

F29987

Suction oil High Pressure Oil

Return to Tank Torque Converter and Lubrication Oil
1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar
7. System pressure test port 20 bar
8. Oil flow to control valve
9. System pressure regulating valve 20 bar
10. Converter circuit safety valve 10 bar
11. Converter system pressure test port 5 bar
12. Torque converter
13. Converter oil temperature port
14. Oil cooler pressure test port
15. Converter pressure by-pass valve 4 bar
16. Oil cooler
17. Oil temperature port after cooler
18. Lubrication pressure port.
19. Lubrication galleries.
 Copyright ©

SECTION 21 - TRANSMISSION 121

SERVO PILOT PRESSURE CIRCUIT

F29988

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
1. Transmission sump 12. 2nd / 1st Solenoid
2. Transmission breather 13. Range modulation solenoid
3. Suction strainer 14. Four wheel drive solenoid
4. Gerotor oil pump 15. High / Low solenoid
5. Pressure oil filter 16. Neutral reverse solenoid
6. Filter by-pass valve 4.3 bar 17. Neutral forward solenoid
7. System pressure test port 20 bar 18. Electronic modulation valve 0-5.5 bar
8. System pressure regulating valve 20 bar 19. Accumulator
9. Oil flow to converter 20. Pressure booster 0-20 bar
10. Oil flow to shift spools 21. Modulated pressure to shift spools 0-20 bar
11. Pressure reducing valve 5.5 bar
 Copyright ©

122 SECTION 21 - TRANSMISSION

SERVO CONTROL FORWARD SECOND GEAR FOUR WHEEL DRIVE ENGAGED

System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and elec-
tronic modulation valve.
When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The high low solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The neutral forward solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The powershift lever will then reduce the current to the modulation valve which gives an output pressure curve
from 0 to 5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is avail-
able for the directional clutches.
Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration.

F29989

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
1. Transmission sump 15. High / Low solenoid
2. Transmission breather 16. Neutral reverse solenoid
3. Suction strainer 17. Neutral forward solenoid
4. Gerotor oil pump 18. Electronic modulation valve 0-5.5 bar
5. Pressure oil filter 20 bar 19. Accumulator
6. Filter by-pass valve 4.3 bar 20. Pressure booster 0-20 bar
7. System pressure test port 20 bar 21. Modulated pressure to shift spools
8. System pressure regulating valve 20 bar
9. Oil flow to converter
10. Oil flow to shift spools 0-20 bar
11. Pressure reducing valve 5.5 bar
12. 2nd / 1st Solenoid
13. Range modulation solenoid
14. Four wheel drive solenoid
 Copyright ©

SECTION 21 - TRANSMISSION 123

SERVO CONTROL FORWARD THIRD GEAR FOUR WHEEL DRIVE ENGAGED

System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and elec-
tronic modulation valve.
Z When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 3rd gear has been engaged the range modulation solenoid will be de-energized.
Z The high/low solenoid prevents pilot oil to flow to the shift spool.
Z The neutral forward solenoid allowing pilot oil to flow to the shift spool.
Z The powershift electronics will then reduce the current to the modulation valve which gives an output pressure
curve from 0-5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is avail-
able for the directional clutch.
Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration.
Z The four wheel drive solenoid supplies pilot oil to the shift spool.

F29990

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
1. Transmission sump 12. 2nd / 1st Solenoid
2. Transmission breather 13. Range modulation solenoid
3. Suction strainer 14. Four wheel drive solenoid
4. Gerotor oil pump 15. High / Low solenoid
5. Pressure oil filter 16. Neutral reverse solenoid
6. Filter by-pass valve 4.3 bar 17. Neutral forward solenoid
7. System pressure test port 20 bar 18. Electronic modulation valve 0-5.5 bar
8. System pressure regulating valve 20 bar 19. Accumulator
9. Oil flow to converter 20. Pressure booster 0-20 bar
10. Oil flow to shift spools 21. Modulated pressure to shift spools 0-20 bar
11. Pressure reducing valve 5.5 bar
 Copyright ©

124 SECTION 21 - TRANSMISSION

SERVO CONTROL REVERSE FIRST GEAR FOUR WHEEL DRIVE ENGAGED

System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and elec-
tronic modulation valve.
When the powershift lever is moved rearward and twisted clock wise a electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 1st gear has been engaged the range modulation solenoid will be de-energized.
Z The low/high solenoid sends pilot oil to the shift spool.
Z The neutral reverse solenoid allowing pilot oil to flow to the shift spool.
Z The powershift lever microprocessor will then reduce the current to the modulation valve which gives an out-
put pressure curve from 0-5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is avail-
able for the directional clutches.
Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration.

F29991

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
1. Transmission sump 12. 2nd / 1st Solenoid
2. Transmission breather 13. Range modulation solenoid
3. Suction strainer 14. Four wheel drive solenoid
4. Gerotor oil pump 15. High / Low solenoid
5. Pressure oil filter 16. Neutral reverse solenoid
6. Filter by-pass valve 4.3 bar 17. Neutral forward solenoid
7. System pressure test port 20 bar 18. Electronic modulation valve 0-5.5 bar
8. System pressure regulating valve 20 bar 19. Accumulator
9. Oil flow to converter 20. Pressure booster 0-20 bar
10. Oil flow to shift spools 21. Modulated pressure to shift spools 0-20 bar
11. Pressure reducing valve 5.5 bar
 Copyright ©

SECTION 21 - TRANSMISSION 125

CONTROL VALVE OPERATION FORWARD, SECOND GEAR WITH FOUR WHEEL DRIVE ENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise a electrical signal is sent to:
Z Oil flows from the system pressure regulating valve at 20 bar through the four wheel drive spool to engage
the 4WD clutch.
Z System pressure also flows through the range modulation valve, then through the 1st 2nd spool to engage
the 2nd gear clutch.
Z The high low solenoid which energizes allowing pilot oil to flow to the shift spool. This will allow oil to flow to
the low clutch.
Z The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward low shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure.
Z The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward low
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.

1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar
7. System pressure test port 20 bar
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. Range modulation restriction
18. Four wheel drive solenoid
19. Four wheel drive shift spool
20. Four wheel drive clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar
31. Accumulator
32. Pressure booster 0-20 bar
 Copyright ©

126 SECTION 21 - TRANSMISSION

Control valve operation forward, second gear with four wheel drive engaged

F29992

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
 Copyright ©

SECTION 21 - TRANSMISSION 127

CONTROL VALVE OPERATION FORWARD, THIRD GEAR WITH FOUR WHEEL DRIVE DISENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids. Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise and the 4WD is switched off a electrical
signal is sent to:
Z The 4WD solenoid, sending pilot pressure to the shift spool.
This will move the spool preventing oil flowing to the clutch disengaging 4WD.
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward high shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure by 4.
The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward high
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.

1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar
7. System pressure test port
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. Range modulation restriction
18. Four wheel drive solenoid
19. Four wheel drive shift spool
20. Four wheel drive clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar
31. Accumulator
32. Pressure booster 0-20 bar
 Copyright ©

128 SECTION 21 - TRANSMISSION

Control valve operation forward, third gear with four wheel drive disengaged

F29993

Suction Oil Return to Tank

High Pressure Oil Pilot Pressure
Torque Converter and Lubrication Oil Modulated Pilot Oil
 Copyright ©

SECTION 21 - TRANSMISSION 129

CONTROL VALVE OPERATION REVERSE, FIRST GEAR WITH FOUR WHEEL DRIVE ENGAGED
Pressure oil from the system regulating valve flows to the pressure reducing valve. The pressure lowers to 5.5
bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve. When the powershift lever is moved rearward, kick-down button is de-
pressed and the 4WD is switched off a electrical signal is sent to:
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z The neutral reverse solenoid which energizes allows pilot pressure to flow to the shift spool. This will allow oil
to flow on to the reverse shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases act-
ing on the boost valve and it multiplies pilot pressure.
Z The oil from the boost valve is modulated allowing a steady increase of pressure to act on the reverse clutch
pack which gradually takes up drive until clutch pressure reaches 20 bar.

1. Transmission sump
2. Transmission breather
3. Suction strainer
4. Gerotor oil pump
5. Pressure oil filter
6. Filter by-pass valve 4.3 bar
7. System pressure test port 20 bar
8. System pressure regulating valve 20 bar
9. Oil to converter circuit
10. Pressure reducing valve 5.5 bar
11. 2nd / 1st Solenoid
12. 2nd / 1st shift spool
13. 2nd gear clutch
14. 1st gear clutch
15. Range modulation solenoid
16. Range modulation spool
17. Four wheel drive solenoid
18. Range modulation restriction
19. Four wheel drive shift spool
20. Four wheel drive clutch
21. High / low solenoid
22. High / low shift spool
23. Forward high clutch
24. Forward low clutch
25. Neutral reverse solenoid
26. Neutral reverse shift spool
27. Reverse clutch
28. Neutral forward solenoid
29. Neutral forward shift spool
30. Electronic modulation valve 0-5.5 bar
31. Accumulator
32. Pressure booster 0-20 bar
 Copyright ©

130 SECTION 21 - TRANSMISSION

Control valve operation reverse, first gear with four wheel drive engaged

F29994

Suction Oil
High Pressure Oil
Torque Converter and Lubrication Oil
Return to Tank
Pilot Pressure
Modulated Pilot Oil
 Copyright ©

SECTION 21 - TRANSMISSION 131

PRESSURE TESTING TORQUE CONVERTER AND COOLER CIRCUIT

All pressure and flow testing should be measured with an oil temperature of 82-93 °C.
For operating speed refer to each test.

Port 1 System pressure.

Z Engine set to 750 revs/min minimum pressure 15 bar.
Z Engine set to 2200 revs/min 19.6-23.1 bar.

Port 2 Torque converter in.

Z Engine set to 2200 revs/min oil pressure range 5-11 bar.

Port 3 Torque converter out.

Z Engine speed 2000 revs/min minimum pressure 2 bar.
Z Engine speed 2200 revs/min maximum pressure 5 bar.

Port 4 Oil temperature converter out.

Z Normal operating temperature 80-90 °C.
Maximum temperature 120 °C.

Port 5 Oil temperature cooler out.

Z T.B.A

Port 6 Lubrication pressure.

Z Engine speed 2000 revs/min pressure range 0.8-2.0 bar.

HYDRAULIC OIL FLOWS

Oil flows to the pressure regulating valve, maintaining system pressure to the control valve and clutches at 20
bar.
Excess oil flow is bleed off to the converter circuit which is protected by a 10 bar safety valve.
Oil enters the converter through the converter blade cavity and exits in the passage between the turbine shaft
and pump drive.
Oil then flow to the external cooler.
Across the converter and oil cooler circuit a by-pass valve is fitted if the pressure difference is more than 4 bar
the valve will open. Directing excess oil to the lubrication circuit.
This protects the system during start up from cold oil or at high revs/min.
After leaving the cooler the oil is directed via a single fitting on the rear of the transmission to a series of tubes
and passages, to lubricate and cool the transmission bearings and clutches.
Oil is drawn up from the sump, via an internal strainer, through the inlet port of the hydraulic pump.
Oil is pumped out to the pressure filter.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than 4.3
bar.
Oil then drains back by gravity to the transmission sump.
 Copyright ©

132 SECTION 21 - TRANSMISSION

2.9 GEAR AND CLUTCH LAY OUT

t
Ou

In

t
Ou

F27735

Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
 Copyright ©

SECTION 21 - TRANSMISSION 133

2.10 TRANSMISSION REMOVAL AND INSTALLATION

REMOVAL

SWARNING
Before performing any service or maintenance on the machine ensure the wheels are chocked / blocked to
prevent the machine from moving.

1. Lower the loader to the ground or raise and secure (dependent upon lifting apparatus) and release any
pressure in the system as required. Apply the handbrake and chock the wheels.
2. Switch off engine.
3. Isolate battery.
4. Remove all engine panels.
5. Remove front cast cowling.
6. Drain engine coolant and remove hoses.

IMPORTANT: air conditioning where fitted - Do not disconnect the air conditioning hoses from the compressor
or condenser unless a refrigerant reclaim system is to be used. Engine / Transmission removal from the ma-
chine does not require the system to be discharged.

Remove the condenser from the front radiator and place the condenser to one side of the chassis.
Disconnect the air conditioning compressor attaching hardware and place the compressor to one side of the
chassis.
Disconnect the expansion bottle connections from the radiator.
7. Remove all attaching bolts from radiator.
8. Disconnect transmission cooler pipes.
9. Remove radiator, taking care not to damage the fan or hydraulic oil cooler.
10. Remove air cleaner assembly.
11. Disconnect all electrical connections.
12. Disconnect hydraulic pipe clamps.
13. Disconnect the fuel tank feed and return pipes.
14. Disconnect the foot throttle cable at the fuel injection pump.
15. Remove the cab mat.
16. Remove the cab floor access panel.
 Copyright ©

134 SECTION 21 - TRANSMISSION

17. Disconnect the 12 pin connector from the trans-

mission valve chest mounted to the left hand
side of the of the transmission.
18. Disconnect the transmission to lock out valve
pipe.
19. Disconnect lock out return pipe and plug the hole
(oil will leak out of transmission).

F27736

20. Remove front drive shaft (where fitted) and re-

move rear drive shaft.
21. Disconnect the hand brake cable.
22. Disconnect and pull back hydraulic pump (leav-
ing all pipes attached). Check that the oil pump
drive shaft does not slide out with the pump.
23. Check return from steering motor is on the out-
side of transmission oil level tube.

F27737

24. With the engine supported and using a “hoist”

capable (1) of supporting a total weight of 800 kg 1
loosen and remove the engine and transmission
mounting bolts.

IMPORTANT: if the hydraulic oil pump is removed

from the transmission / engine assembly the bal-
ance of the assembly when hoisted will be front end
heavy.

25. Using lifting tool 380000676 very carefully raise

and guide the engine/transmission assembly
from the vehicle. F27738
 Copyright ©

SECTION 21 - TRANSMISSION 135

SEPARATING ENGINE FROM TRANSMISSION

1. Place the engine/transmission assembly on a
suitable splitting stand.
2. Remove the starter motor assembly.

F27739

3. Unscrew and remove the torque converter at-

taching bolts accessed through the starter motor 1
aperture (1).
4. Remove the engine timing tab (2).
5. Unscrew and remove the bell housing bolts.
6. Gently slide the transmission with the torque
converter from the engine.

2
F27740

INSTALLATION
Place a stud in one tang of the flexi plate and as the
transmission is assembled up to the engine guide
the stud through a bolt hole of the flywheel, remove
the stud and refit a bolt.
Refit the attaching bolts which couple the transmis-
sion to engine.
Turn the engine crankshaft using a torque bar to ex-
pose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts.
Hoist the engine / transmission assembly back into
the vehicle and centralize in the machine using a
measure between the chassis and centre line of the
crankshaft pulley. This ensures the engine is cen-
trally positioned before torque up of the engine /
transmission to chassis bolts.
Reconnect all ancillary equipment as previously de-
scribed.
Ensure all attaching hardware is tightened to the
correct torque value as detailed in the specifications.
Ensure after installation that all fluid levels are cor-
rect prior to start up.
Start and run the engine until correct operating tem-
perature is achieved to purge air from cooling sys-
tem.
Stop engine, check for leaks, rectify as required and
recheck fluid levels.
 Copyright ©

136 SECTION 21 - TRANSMISSION

TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

Remove all burrs from flywheel (1) mounting face
and nose pilot bore (3). Clean drive plate surface
1
with solvent.
A
Check engine flywheel (4) and housing (1).
Measure and record engine crankshaft end play.
Install two 63.500 mm long transmission to flywheel
housing guide studs in the engine flywheel housing
as shown. Rotate the engine flywheel to align a drive
plate mounting screw hole with the flywheel housing 3
access hole (3).

Install a 101.60 mm long drive plate locating stud 4

fine thread in a drive plate nut. Align the locating stud
in the drive plate with the flywheel drive plate (5)
mounting screw hole.
(Does not apply to units having 3 intermediate drive
plates).

Rotate the transmission torque converter to align the

locating stud in the drive plate with the flywheel drive
plate mounting screw hole (3). Locate transmission
on flywheel housing (1).

Aligning drive plate to flywheel and transmission to 2

flywheel housing guide studs, install transmission to
flywheel housing screws. Tighten screws to speci-
fied torque. Remove transmission to engine guide 5
studs. Install remaining screws and tighten to speci- F27742

fied torque.

Remove drive plate locating stud.

Install drive plate attaching screw and washer. 6

Snug screw but do not tighten. Some engine fly-
wheel housings have a hole located on the flywheel
housing circumference in line with the drive plate
screw access hole. A screwdriver or pry bar used to
hold the drive plate against the flywheel will facilitate
installation of the drive plate screws. Rotate the en- 7
gine flywheel and install the remaining seven fly-
wheel to drive plate attaching screws. Snug screws
8
but do not tighten.
After all eight screws are installed torque one torque
35 - 39 Nm. This will require tightening each screw
and rotating the engine flywheel until the full amount
of eight screws have been tightened to specified
torque. F27743

Measure engine crankshaft end play after transmis-

sion has been completely installed on engine fly-
wheel.
This value must be within 0.025 mm of the end.
6. Special stud, washer and self locknut furnished
by engine manufacturer
7. Impeller cover
8. Intermediate drive plate
 Copyright ©

SECTION 21 - TRANSMISSION 137

2.11 TRANSMISSION COMPONENTS

CONVERTER HOUSING AND TRANSMISSION

ITEM DESCRIPTION QUANTITY

1 Plug 11
2 O-ring 11
3 O-ring 3
4 Plug 3
5 Ball 1
 Copyright ©

138 SECTION 21 - TRANSMISSION

ITEM DESCRIPTION QUANTITY

6 Spring 1
7 Plug 1
8 O-ring 1
9 Spring safety valve 1
10 Ball 1
11 O-ring 1
12 Plug 1
13 O-ring converter housing to transmission case 2
14 O-ring converter housing to transmission case 2
15 Gasket converter housing to transmission case 1
16 Housing converter 1
17 Lock washer - converter housing to transmission case screw 14
18 Screw - converter housing to transmission case 14
19 O-ring filter adaptor 1
20 O-ring filter adaptor 1
21 Filter - adaptor 1
22 Lock washer - filter adaptor screw 3
23 Screw - filter adaptor 3
24 Assembly - filter 1
25 Oil seal - output shaft front 1
26 Screw - converter housing to transmission case 1
27 Lock washer - converter housing to transmission case screw 1
28 Screw - converter housing to transmission case 5
29 Lock washer - converter housing to transmission case screw 5
30 Clip - suction tube 1
31 Lock washer - suction tube screw 1
32 Screw - suction tube 1
33 O-ring suction tube 1
34 Retainer - suction tube 1
35 Assembly - tube and filter 1
36 Baffle - oil 1
37 Lock washer - oil baffle mounting screw 3
38 Screw - oil baffle mounting 3
39 Nut - oil baffle mounting screw 5
40 Lock washer - oil baffle mounting screw 5
41 Baffle - oil 1
42 Screw - oil baffle mounting 5
43 Plate - oil baffle 1
44 Plate - oil baffle 1
45 Pin - transmission case to converter dowel 2
 Copyright ©

SECTION 21 - TRANSMISSION 139

ITEM DESCRIPTION QUANTITY

46 Lock washer - converter housing to transmission case screw 4
47 Screw - converter housing to transmission case 4
48 Case - transmission 1
49 O-ring 1
50 Plug 1
51 Plug 11
52 O-ring 11
53 Seal upper output 1
54 Screw - converter housing to transmission case 5
55 Lock washer - converter housing to transmission case screw 5
56 Plug - magnetic drain 1
57 Snap ring - output shaft rear bearing 1
58 Plug - output shaft bore 1
59 Sealing ring - plug 1
60 Plug 1
61 Plug 1
62 Plug 1
 Copyright ©

140 SECTION 21 - TRANSMISSION

INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE

ITEM DESCRIPTION QUANTITY

1 Screw - drive plate mounting 6
2 Lock washer - drive plate mounting screw 6
3 Ring - drive plate 1
 Copyright ©

SECTION 21 - TRANSMISSION 141

ITEM DESCRIPTION QUANTITY

4 Plate - drive 2
5 Assembly - drive plate 1
6 Bushing - converter pilot 1
7 Assembly - torque converter 1
8 Oil seal - charging pump 1
9 Screw - pump mounting 6
10 Seal washer - pump mounting screw 6
11 Assembly - charging pump 1
12 O-ring charging pump 1
13 Ring - piston 1
14 Bearing - input shaft front 1
15 Snap ring 1
16 Snap ring 8
17 Gear - forward low and reverse drive 9
18 Snap ring 1
19 Shaft - input 1
20 Snap ring 1
21 Gear - forward high drive 1
22 Bearing - input shaft rear 1
23 Ring - piston 1
24 Assembly - pump drive shaft and sleeve 1
25 Ring - piston 1
26 Bearing - pump drive shaft 1
27 Snap ring 1
28 Retaining ring 1
29 Gasket - permanent pump adapter cover 1
30 Cover - permanent pump adapter 1
31 Lock washer - permanent pump adapter cover screw 4
32 Screw - permanent pump adapter cover 4
 Copyright ©

142 SECTION 21 - TRANSMISSION

FORWARD LOW AND FORWARD HIGH SHAFT

18
17
5
4
2 3

1
16
15
14
13
12
11
10
9
8
7
6 32
31
30
29

28
27

26

25
50
24
49
23 48
22 47
46
21
20 45
19
44
43
42

41
40
39
38

37
36
34 35
33
F27746

ITEM DESCRIPTION QUANTITY

1 Bearing - front FWD low/FWD high shaft 1
2 Gear - forward driven 1
3 Snap ring 1
 Copyright ©

SECTION 21 - TRANSMISSION 143

ITEM DESCRIPTION QUANTITY

4 Bearing - clutch gear 1
5 Retaining ring - clutch gear bearing 1
6 Gear forward low clutch 1
7 Ring - clutch gear piston 1
8 Retaining ring - clutch gear bearing 1
9 Bearing - clutch gear 1
10 Snap ring 1
11 Snap ring 1
12 Washer 1
13 Snap ring - backing plate 1
14 Plate - clutch disc backing 1
15 Disc - outer half 1
16 Disc - outer 8
17 Disc - inner 9
18 Disc - outer half 1
19 Ring - retaining 1
20 Retainer spring 1
21 Spring - piston return 1
22 Plate spring - clutch piston wear 1
23 Assembly - clutch piston and seals 1
24 Seal - clutch piston - outer 1
25 Seal - clutch piston - inner 1
26 Assembly forward low/forward high, shaft drum and plug 1
27 Seal - clutch piston - inner 1
28 Seal - clutch piston - outer 1
29 Assembly clutch piston and seals 1
30 Plate spring clutch piston wear 1
31 Spring piston return 1
32 Retainer spring 1
33 Spacer clutch spring fwd high 1
34 Ring - retaining 1
35 Disc - outer half 1
36 Disc - inner 4
37 Disc - outer 3
38 Disc - outer half 1
39 Plate - clutch disc backing 1
40 Spacer - clutch disc backing plate Fwd/high 1
41 Snap ring spacer 1
42 Thrust washer 1
43 Thrust bearing 1
 Copyright ©

144 SECTION 21 - TRANSMISSION

ITEM DESCRIPTION QUANTITY

44 Bearing - needle 1
45 Gear - forward high clutch 1
46 Bearing - needle 1
47 Thrust bearing 1
48 Thrust washer 1
49 Bearing - rear Fwd low/Fwd high shaft 1
50 Ring - piston 3
 Copyright ©

SECTION 21 - TRANSMISSION 145

REVERSE / 1ST SHAFT AND GEARS

9
8
7
6

5
4
2 3

18
1 16 17

15
14 32
13
12
11
31
10
30
29
27 28

26
47
25
46
24 45

23 44
22 43
21
42
20
19
41
40

39
37 38
36

34 35
33
F27747
 Copyright ©

146 SECTION 21 - TRANSMISSION

ITEM DESCRIPTION QUANTITY

1 Bearing - front reverse: 1st shaft 1
2 Gear - reverse driven 1
3 Snap ring 1
4 Bearing - clutch gear 1
5 Retaining ring - clutch gear bearing 1
6 Gear forward low clutch 1
7 Ring - clutch gear piston 1
8 Retaining ring - clutch gear bearing 1
9 Bearing - clutch gear 1
10 Snap ring 1
11 Snap ring 1
12 Washer 1
13 Snap ring - backing plate 1
14 Plate - clutch disc backing 1
15 Disc - outer half 1
16 Disc - outer 8
17 Disc - inner 9
18 Disc - outer half 1
19 Ring - retaining 1
20 Retainer spring 1
21 Spring - piston return 1
22 Plate spring - clutch piston wear 1
23 Assembly - clutch piston and seals 1
24 Seal - clutch piston - outer 1
25 Seal - clutch piston - inner 1
26 Assembly reverse / 1st, shaft drum and plug 1
27 Seal - clutch piston - outer 1
28 Seal - clutch piston - inner 1
29 Assembly clutch piston and seals 1
30 Plate clutch piston wear 1
31 Assembly - spring disc 1
32 Ring - retaining 1
33 Disc - outer half 1
34 Disc - inner 9
35 Disc - outer 8
36 Disc - outer half 1
37 Modulation spring 1
38 Plate - clutch disc backing 1
39 Snap ring - clutch disc backing plate 1
40 Bearing clutch gear 1
 Copyright ©

SECTION 21 - TRANSMISSION 147

ITEM DESCRIPTION QUANTITY

41 Retaining ring - clutch gear bearing 1
42 Gear - 1st clutch 1
43 Retaining ring - clutch gear bearing 1
44 Bearing clutch gear 1
45 Snap ring 1
46 Bearing - rear reverse / 1st shaft 1
47 Ring - piston 3
 Copyright ©

148 SECTION 21 - TRANSMISSION

2ND SHAFT

7
6

5
4

3
2
15
14
1 13

12
11
10
9
8

23

22

21

20
31
19
30
18 29

17
28
16
27

26

25
24

F27748
 Copyright ©

SECTION 21 - TRANSMISSION 149

ITEM DESCRIPTION QUANTITY

1 Ring - piston 2
2 Bearing - front 2nd shaft 1
3 Washer - bearing support 1
4 Bearing clutch gear 1
5 Retaining - ring clutch gear bearing 1
6 Gear - 2nd clutch 1
7 Retaining ring - clutch gear bearing 1
8 Bearing - clutch gear 1
9 Snap ring - clutch disc backing plate 1
10 Plate - clutch disc backing 1
11 Modulation spring 1
12 Disc - outer half 1
13 Disc - outer 8
14 Disc - inner 9
15 Disc - outer half 1
16 Ring retaining 1
17 Retainer spring 1
18 Spring clutch - piston return 1
19 Plate spring - clutch piston wear 1
20 Assembly - clutch piston and seals 1
21 Seal - clutch piston - outer 1
22 Seal - clutch piston - inner 1
23 Assembly - 2nd shaft, drum and plug 1
24 Snap ring - gear retainer 1
25 Gear - lower output drive 1
26 Gear - upper output 1
27 Bearing rear - 2nd shaft 1
28 Flange yoke 1410 - upper output 1
29 O-ring - flange 1
30 Washer - flange nut 1
31 Nut - flange 1
 Copyright ©

150 SECTION 21 - TRANSMISSION

OUTPUT SHAFT WITH INTERNAL DISCONNECT

13

12
11

10

8
7

5
4

22
3 21
2
1 20
19
18

17
16
15

32
31

30
29
28
14

27
26

25

24

23
F27749

ITEM DESCRIPTION QUANTITY

1 Nut - flange 1
2 Washer - flange nut 1
3 O-ring - flange 1
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SECTION 21 - TRANSMISSION 151

ITEM DESCRIPTION QUANTITY

4 Output flange front yoke 1410 with brake pads 1
5 Bearing - output shaft front 1
6 Ring - retaining 1
7 Disconnect hub 1
8 Snap ring - gear retainer 1
9 Assembly - output shaft front 1
10 Bushing 2
11 Snap ring - clutch disc backing plate 1
12 Spacer 1
13 Plate clutch disc backing 1
14 Disc - outer half 1
15 Disc - outer 11
16 Disc - inner 12
17 Disc - outer half 1
18 Ring - retaining 1
19 Retainer spring 1
20 Spring - piston return 1
21 Plate spring - clutch piston wear 1
22 Assembly - clutch piston and seals 1
23 Seal - clutch piston - outer 1
24 Seal - clutch piston - inner 1
25 Assembly - output shaft rear, drum and plug 1
26 Snap ring - gear retainer 1
27 Gear lower output 1
28 Snap ring gear retainer 1
29 Snap ring - rear bearing 1
30 Bearing - output shaft rear 1
31 Snap ring - rear bearing 1
32 Ring - piston 3
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152 SECTION 21 - TRANSMISSION

PARKING BRAKE

19

20
3

19

2 18

1
17
21

15
16
14

12 13

11

10

9
8
7
6
5
4
F27750

ITEM DESCRIPTION QUANTITY

1 Screw - brake mounting 2
2 Assembly - caliper 1
3 Nut - brake mounting screw 2
4 Nut - jam adjustment 1
5 Nut - adjustment 1
6 Washer - hardened 1
7 Washer - stainless steel 1
8 Washer - thrust 1
9 Lever 1
10 Boot 1
11 Cam 1
12 Id seal 1
13 Ball bearing 3
14 Plastic retainer 1
15 Cam 1
16 Torque plate - front 1
17 Pads assembly 2
18 Torque plate - rear 1
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SECTION 21 - TRANSMISSION 153

ITEM DESCRIPTION QUANTITY

19 Sleeve mounting 2
20 Bolt - Adjusting 1
21 Spring 1
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154 SECTION 21 - TRANSMISSION

ELECTRICAL CONTROL VALVE

6 3

5 F27751

ITEM DESCRIPTION QUANTITY

1 Control valve assembly 1
2 Control valve mounting screws 17
3 Control valve protection cover gasket 1
4 Control valve protection cover 1
5 Protection cover screw 20
6 Air breather 1
 Copyright ©

SECTION 21 - TRANSMISSION 155

2.12 DISASSEMBLY AND ASSEMBLY

ASSEMBLY INSTRUCTIONS

1 10 6 7
3

14 6

15

2
4
5

10
2
13
15
2
10

10 3

16 11

12
3
15

11
3
8

F27752

1. Add some grease to O-ring before assembly.

2. Add some grease to piston rings before assembly slots of piston rings are not allowed to pass bores in
housings.

156 SECTION 21 - TRANSMISSION
3. Teflon seals must be sized prior to assembly,
add some grease to inner and outer diameter of
clutch drum before assembly.
4. Pump must be filled up with test oil prior to as-
sembly.
5. Pump drive shaft must be installed after torque
converter.
6. Forward low, reverse, 1st, and 2nd clutch: 9
separator plates with inner splines. 8 friction
plates (friction material both sides) with outer
splines, 2 1-side friction plates (friction material
1 side) with outer splines.
Start with one 1-side friction plate, metal against
piston, then alternately separator and friction
plate.
End with a 1-side friction plate, metal side
against end plate or disc spring.
Be sure disc spring is mounted as shown.
• Clearance: Forward low and Reverse:
min. clearance = 2.79 mm (for carbon plates)
max. clearance = 5.21 mm (for carbon plates)
If clearance is more than 4.79 mm, add one
separator plate upon last separator plate.
• Clearance: First and second:
min. clearance = 2.54 mm
max. clearance = 5.41 mm
If clearance is more than 4.54 mm, add one
separator plate upon last separator plate.
7. • Forward high clutch: 4 separator plates, 3 fric-
tion plates and two 1-side friction plates.
• Assembly see (6)
• Clearance:
min. clearance = 1.24 mm (for carbon plates)
max. clearance = 2.76 mm (for carbon plates)
8. • Disconnect clutch: 12 separator plates, 11 fric-
tion plates and two 1-side friction plates.
Copyright ©
• Assembly see (6)
• Clearance:
min. clearance = 3.66 mm (for carbon plates)
max. clearance = 6.78 mm (for carbon plates)
If clearance is more than 5,66 mm, add one
separator plate upon last separator plate.
9. • Installation force of disc spring is 3280 N.
10. Be sure that shielded and sealed bearings are
mounted as shown.
11. Seals must be pressed in perpendicular upon
shaft axis from bearing side. Except lower rear
output.
12. Plug to be screwed in and torqued but without
Loctite.
13. First clutch springs concave side of first disc
spring to be placed against clutch piston wear
sleeve.
Remaining 10 springs to be stacked alternately
reversed as shown.
14. Shipping strap: only used during shipment of the
individual transmission.
NOTE: check if safety valve and valve block are
tested before assembly.
15. Heat gears up to 150 °C before assembling.
16. Parking brake.
17. Mounting: tighten locking nuts with 0.25 to 1.25
mm clearance between nuts and sleeves.
Adjustment: loosen the (2) adjustment locking
nuts (1 and 2). Put lever in correct position.
Tighten inner adjustment nut (2) with 11 Nm.
Back off inner adjustment nut (2).
Tighten outer locking nut (1) against inner ad-
justment nut (2). Clearance must be from 0.8 to
1.1 mm.
F27753
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SECTION 21 - TRANSMISSION 157

DISASSEMBLY TRANSMISSION
Remove oil filter.

Remove filter adapter screws.

Remove filter adapter with O-ring.

Remove drive plate screws.

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158 SECTION 21 - TRANSMISSION

Remove drive plates.

Remove torque converter as an assembly.

Remove charging pump screws.

Use a bearing puller to remove charging pump.

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SECTION 21 - TRANSMISSION 159

Remove charging pump as an assembly, remove O-

ring.

Remove parking brake mounting screws.

Remove parking brake as an assembly.

Remove upper output nut, washer, O-ring and

flange.
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160 SECTION 21 - TRANSMISSION

Remove air breather.

Remove control valve protection cover mounting

screws.

Remove wiring connector mounting nut.

Remove control valve protection cover and gasket.

 Copyright ©

SECTION 21 - TRANSMISSION 161

Remove control valve mounting screws.

Remove control valve as an assembly: remove by-

pass valve spool and spring in the meantime.

Remove auxiliary pump hole cover screws.

Remove auxiliary pump hole cover and gasket.

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162 SECTION 21 - TRANSMISSION

Remove pump drive shaft rear bearing locating ring.

Remove pump drive shaft and bearing as an

assembly.

Remove upper output nut, washer, O-ring and

flange.

Remove converter housing to transmission case

screws and lock washers.
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SECTION 21 - TRANSMISSION 163

Remove transmission case plug.

Transmission case plug and gasket removed.

Spread ears on output shaft rear bearing retaining

ring. Holding snap ring open, tap on output shaft and
transmission case to remove case from converter
housing.
Lift transmission case from converter housing (using
lifting bracket).

Transmission case removed all drums and shafts

remain in converter housing.
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164 SECTION 21 - TRANSMISSION

Remove transmission case to converter housing

gasket.

Remove output shaft sealing rings.

Remove output shaft rear bearing retaining ring.

Use bearing puller to remove output shaft rear

bearing.
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SECTION 21 - TRANSMISSION 165

Output shaft rear bearing removed.

Using bearing puller to remove 2nd shaft rear

bearing.

2nd shaft rear bearing removed.

Using bearing puller to remove input shaft rear

bearing.
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166 SECTION 21 - TRANSMISSION

Input shaft rear bearing removed.

Remove reverse and 1st shaft sealing rings.

Using bearing puller to remove reverse and 1st shaft

rear bearing.

Reverse and 1st shaft rear bearing removed.

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SECTION 21 - TRANSMISSION 167

Remove forward low and forward high shaft sealing

rings.

Using bearing puller to remove forward low and

forward high shaft rear bearing.

Forward low and forward high shaft rear bearing

removed.

Use bearing puller to remove forward high gear from

the input shaft.
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168 SECTION 21 - TRANSMISSION

Forward high gear removed.

Remove baffle plates screws, remove baffle plates.

Remove oil baffle to converter housing screws, do

not remove oil baffle from output shaft.

Remove output shaft, 2nd shaft and oil baffle at the

same time.
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SECTION 21 - TRANSMISSION 169

Loosen suction tube retainer screw.

Remove suction tube retainer screw and lock washer.

Remove suction tube retainer ring.

Remove suction tube O-ring and washer.

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170 SECTION 21 - TRANSMISSION

Remove output shaft front bearing retainer ring.

Remove output shaft front assembly.

Remove input shaft, reverse and forward shaft at the

same time.

Remove safety valve plug, spring and ball.

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SECTION 21 - TRANSMISSION 171

Remove by-pass plug, spring and ball.

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172 SECTION 21 - TRANSMISSION

FORWARD HIGH CLUTCH DISASSEMBLY

Remove clutch shaft sealing rings.

Remove thrust washer and thrust bearing.

Remove clutch gear outer needle bearing.

Remove clutch gear.

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SECTION 21 - TRANSMISSION 173

Remove clutch gear inner needle bearing.

Remove thrust washer and thrust bearing.

Remove backing plate retaining ring.

Remove clutch plate spacer.

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174 SECTION 21 - TRANSMISSION

Remove clutch disc backing plate.

Remove one outer half disc.

Remove inner and outer discs.

Remove one outer half disc.

 Copyright ©

SECTION 21 - TRANSMISSION 175

Compress spring to remove spring retainer snap

ring.

Remove spring retainer snap ring.

Remove clutch spring spacer.

Remove clutch piston spring retainer.

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176 SECTION 21 - TRANSMISSION

Remove clutch piston spring.

Remove clutch piston wear plate.

Remove clutch piston assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 177

FORWARD LOW CLUTCH DISASSEMBLY

Use bearing puller to remove front bearing and gear.

Front bearing and gear removed.

Remove gear retainer ring.

Use a bearing puller to remove clutch gear and outer

bearing.
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178 SECTION 21 - TRANSMISSION

Clutch gear and outer bearing removed.

Remove spacer snap ring.

Remove spacer.

Remove backing plate retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 179

Remove clutch disc backing plate.

Use a bearing puller to remove clutch gear inner

bearing.

Clutch gear inner bearing removed.

Remove one outer half disc.

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180 SECTION 21 - TRANSMISSION

Remove inner and outer discs.

Remove one outer half disc.

Remove clutch gear inner bearing locating ring.

Compress spring to remove spring retainer snap

ring.
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SECTION 21 - TRANSMISSION 181

Remove spring retainer snap ring.

Remove clutch piston spring retainer.

Remove clutch piston spring.

Remove clutch piston wear plate.

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182 SECTION 21 - TRANSMISSION

Remove clutch piston assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 183

FORWARD LOW CLUTCH ASSEMBLY

Install clutch piston outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install clutch piston inner seal.

Install clutch piston in clutch drum, use caution as
not to damage sealing rings.

Install clutch piston wear plate on piston.

Install clutch piston spring.

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184 SECTION 21 - TRANSMISSION

Install clutch piston spring retainer.

Install clutch spring retainer snap ring.

Use a sleeve with the proper diameter to fit over

shaft and against retainer ring. A sharp blow with a
soft hammer will compress spring and seat retainer
ring.
Be sure ring is in full position in groove.

Install one outer half disc, with friction material away

from the piston.
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SECTION 21 - TRANSMISSION 185

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.

Install one outer half disc with friction material down.

Install backing plate.

Install backing plate snap ring.

 Copyright ©

186 SECTION 21 - TRANSMISSION

Install spacer.

Install spacer snap ring.

Install inner bearing snap ring.

Install clutch gear inner bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 187

Tap inner bearing into place.

Install clutch gear bearing locating rings.

Install clutch gear sealing ring. Install clutch gear in

clutch drum. Align splines on clutch gear with all in-
ternal teeth of steel discs. Do not force this opera-
tion. Gear splines must be in full position with
internal teeth of all inner discs.

Install clutch gear outer bearing.

Be sure that bearing shield is on the outside.
 Copyright ©

188 SECTION 21 - TRANSMISSION

Tap outer bearing into place.

Install outer bearing snap ring.

Warm gear to 150 °C, install gear.

Warm front bearing to 120 °C, install bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 189

FORWARD HIGH CLUTCH ASSEMBLY

Install clutch outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install piston inner seal and install clutch piston in

clutch drum; use caution as not to damage sealing
rings.

Install clutch piston wear plate on piston.

Install clutch piston return spring.

 Copyright ©

190 SECTION 21 - TRANSMISSION

Install piston return spring retainer.

Install spring retainer spacer.

Install clutch spring retainer snap ring.

Use a sleeve with the proper diameter to fit over

shaft and against retainer ring. A sharp blow with a
soft hammer will compress spring and seat retainer
ring.
Be sure ring is in full position in groove.
 Copyright ©

SECTION 21 - TRANSMISSION 191

Install one outer half disc with friction material away

from the piston.

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed, first and last discs are
steel.

Install one outer half disc with friction material down.

Install backing plate.

 Copyright ©

192 SECTION 21 - TRANSMISSION

Install backing plate spacer.

Install backing plate spacer retainer ring.

Install thrust washer and thrust bearing.

Install clutch gear inner needle bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 193

Install clutch gear in clutch drum. Align splines on

clutch gear with internal teeth of steel discs.
Do not force this operation. Gear splines must be in
full position with internal teeth of all inner discs.

Install clutch gear outer needle bearing.

Install thrust washer and thrust bearing.

Install clutch shaft sealing rings.

 Copyright ©

194 SECTION 21 - TRANSMISSION

FIRST CLUTCH DISASSEMBLY

Remove clutch shaft sealing rings.

Remove clutch gear bearing retainer ring.

Use a bearing puller to remove clutch gear and outer

bearing.

Clutch gear and outer bearing removed.

 Copyright ©

SECTION 21 - TRANSMISSION 195

Remove backing plate retainer ring.

Remove backing plate.

Remove modulation spring.

Use bearing puller to remove clutch gear inner bear-

ing.
 Copyright ©

196 SECTION 21 - TRANSMISSION

Clutch gear inner bearing removed.

Remove one outer half disc.

Remove inner and outer discs.

Remove one outer half disc.

 Copyright ©

SECTION 21 - TRANSMISSION 197

Compress clutch piston belleville washer spring.

Remove spring snap ring.

NOTE: force of disc spring is 3280N.

Spring retainer ring removed.

Remove disc belleville washer spring.

Remove clutch piston wear sleeve.

 Copyright ©

198 SECTION 21 - TRANSMISSION

Remove clutch piston assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 199

REVERSE CLUTCH DISASSEMBLY

Use a bearing puller to remove gear and front
bearing.

Gear and front bearing removed.

Remove clutch gear bearing retaining ring.

Use a bearing puller to remove clutch gear and

clutch gear outer bearing.
 Copyright ©

200 SECTION 21 - TRANSMISSION

Clutch gear and outer bearing removed.

Remove spacer snap ring.

Remove spacer.

Remove backing plate retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 201

Remove clutch disc backing plate.

Use a bearing puller to remove clutch gear inner

bearing.

Clutch gear inner bearing removed.

Remove one outer half disc.

 Copyright ©

202 SECTION 21 - TRANSMISSION

Remove inner and outer discs.

Remove one outer half disc.

Remove inner bearing locating ring.

Compress spring to remove spring retainer snap

ring.
 Copyright ©

SECTION 21 - TRANSMISSION 203

Remove spring retainer snap ring.

Remove clutch piston spring retainer.

Remove clutch piston spring.

Remove clutch piston wear plate.

 Copyright ©

204 SECTION 21 - TRANSMISSION

Remove clutch piston assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 205

REVERSE CLUTCH ASSEMBLY

Install clutch piston outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install clutch piston inner seal. Install clutch piston in

clutch drum, use caution as not to damage sealing
rings.

Install piston wear plate on piston.

Install clutch piston spring.

 Copyright ©

206 SECTION 21 - TRANSMISSION

Install clutch piston spring retainer.

Install clutch spring retainer snap ring.

Use a sleeve with the proper diameter to fit over

shaft and against retainer ring. A sharp blow with a
soft hammer will compress spring and seat retainer
ring.
Be sure ring is in full position in groove.

Install one outer half disc, with friction material away

from the piston.
 Copyright ©

SECTION 21 - TRANSMISSION 207

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.

Install one outer half disc with friction material down.

Install backing plate.

Install backing plate snap ring.

 Copyright ©

208 SECTION 21 - TRANSMISSION

Install spacer.

Install spacer snap ring.

Install inner bearing snap ring.

Install clutch gear inner bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 209

Tap inner bearing into place.

Install clutch gear bearing locating rings.

Install clutch gear sealing ring. Install clutch gear in

clutch drum. Align splines on clutch gear with
internal teeth of steel discs. Do not force this
operation. Gear splines must be in full position with
internal teeth of all inner discs.

Install clutch gear outer bearing.

SWARNING
Be sure that bearing shield is on the outside.
 Copyright ©

210 SECTION 21 - TRANSMISSION

Tap outer bearing into place.

Install outer bearing snap ring.

Warm gear to 150 °C, install gear.

Warm front bearing to 120 °C, install bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 211

FIRST CLUTCH ASSEMBLY

Install clutch piston outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install piston inner seal. Install clutch piston in clutch

drum. Use caution as not to damage sealing rings.

Install clutch piston wear sleeve.

Install piston return disc springs. First spring with

large diameter of bevel toward wear sleeve.
Alternate eleven (11) springs.
 Copyright ©

212 SECTION 21 - TRANSMISSION

Install disc belleville washer spring retainer ring.

Compress spring to install spring retainer ring.

Be sure ring is in full position in groove.

Install one outer half disc with friction material away

from the piston.

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.
 Copyright ©

SECTION 21 - TRANSMISSION 213

Install one outer half disc with friction material down.

Install modulator spring with large diameter up to the

backing plate.

Install backing plate.

Install backing plate snap ring.

 Copyright ©

214 SECTION 21 - TRANSMISSION

Install clutch disc hub inner bearing.

Tap inner bearing into place.

Install clutch hub bearing locating rings. Install clutch

gear in clutch drum. Align splines on clutch gear with
internal teeth of steel discs. Do not force this opera-
tion. Gear splines must be in full position with inter-
nal teeth of all steel discs.

Install clutch hub outer bearing.

Be sure that bearing shield is on the outside.
 Copyright ©

SECTION 21 - TRANSMISSION 215

Tap outer bearing into clutch hub.

Install outer bearing retaining ring.

Install clutch shaft sealing rings.

 Copyright ©

216 SECTION 21 - TRANSMISSION

2ND CLUTCH DRUM DISASSEMBLY

Press upper output gear from 2nd shaft.

Press gear from 2nd shaft.

Remove gear retaining ring.

Remove clutch shaft sealing rings.

 Copyright ©

SECTION 21 - TRANSMISSION 217

Use bearing puller to remove clutch hub and front

bearing.

Remove clutch shaft front bearing.

Remove bearing washer.

Remove clutch hub and outer bearing.

 Copyright ©

218 SECTION 21 - TRANSMISSION

Use a bearing puller to remove clutch hub inner

bearing.

Remove clutch hub inner bearing.

Remove backing plate snap ring.

Remove backing plate.

 Copyright ©

SECTION 21 - TRANSMISSION 219

Remove modulation spring.

Remove one outer half disc.

Remove inner and outer discs.

Remove one outer half disc.

 Copyright ©

220 SECTION 21 - TRANSMISSION

Compress spring to remove spring retaining ring.

Remove spring retaining ring.

Remove spring retainer.

Remove clutch piston return spring.

 Copyright ©

SECTION 21 - TRANSMISSION 221

Remove piston wear plate.

Remove clutch piston assembly.

 Copyright ©

222 SECTION 21 - TRANSMISSION

2ND CLUTCH DRUM ASSEMBLY

Install piston outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install clutch piston inner seal.

Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Install piston wear plate.

Install piston return spring.

 Copyright ©

SECTION 21 - TRANSMISSION 223

Install spring retainer.

Install spring retainer snap ring.

Use a sleeve with the proper inner diameter to fit

over shaft and against retainer ring. A sharp blow
with a soft hammer will compress spring and seat re-
tainer ring. Be sure ring is in full position in groove.

Install one outer half disc with friction material away

from the piston.
 Copyright ©

224 SECTION 21 - TRANSMISSION

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.

Install one outer half disc with friction material down.

Install modulator spring with large diameter up to the

backing plate.

Install backing plate.

 Copyright ©

SECTION 21 - TRANSMISSION 225

Install backing plate retainer ring.

Install clutch hub inner bearing.

Tap clutch gear inner bearing into place.

Install clutch hub bearing locating rings. Install clutch

gear in clutch drum. Align splines on clutch gear with
internal teeth of steel discs. Do not force this opera-
tion.
Gear splines must be in full position with internal
teeth of all steel discs.
 Copyright ©

226 SECTION 21 - TRANSMISSION

Install clutch hub outer bearing.

SWARNING
Be sure that bearing shield is on the outside.

Tap outer bearing into place.

Install bearing washer.

Warm front bearing to 120 °C, install bearing.

 Copyright ©

SECTION 21 - TRANSMISSION 227

Install clutch shaft sealing rings.

Install gear retaining ring.

Warm gear to 150 °C, install gear.

Warm upper output gear to 150 °C install gear.

 Copyright ©

228 SECTION 21 - TRANSMISSION

OUTPUT SHAFT DISASSEMBLY

Remove oil baffle screws and nuts.

Remove oil baffle.

Remove output shaft sealing rings.

Remove output shaft gear retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 229

Press output gear from shaft.

Remove output gear.

Remove oil baffle from output shaft.

Remove gear retaining ring.

 Copyright ©

230 SECTION 21 - TRANSMISSION

Remove backing plate snap ring.

Remove backing plate spacer.

Remove backing plate.

Remove one outer half disc.

 Copyright ©

SECTION 21 - TRANSMISSION 231

Remove inner and outer discs.

Remove one outer half disc.

Compress spring to remove spring retaining ring.

Remove spring retaining ring.

 Copyright ©

232 SECTION 21 - TRANSMISSION

Remove spring retainer.

Remove clutch piston spring.

Remove piston wear plate.

Remove piston assembly.

 Copyright ©

SECTION 21 - TRANSMISSION 233

OUTPUT SHAFT ASSEMBLY

Install piston outer seal.

NOTE: ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with out-
er diameter of piston.

Install clutch piston inner seal.

Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

Install piston wear plate on piston.

Install clutch piston spring.

 Copyright ©

234 SECTION 21 - TRANSMISSION

Install spring retainer.

Install spring retainer snap ring. Use a sleeve with

the proper inner diameter to fit over shaft and
against snap ring. A sharp blow of a soft hammer will
compress spring and seat retainer ring. Be sure ring
is in full position in groove.

Install one outer half disc with friction material away

from the piston.

Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.
 Copyright ©

SECTION 21 - TRANSMISSION 235

Install one half disc with friction material down.

Install backing plate.

Install backing plate spacer.

Install backing plate snap ring.

 Copyright ©

236 SECTION 21 - TRANSMISSION

Install oil baffle on output shaft.

Install output gear retaining ring.

Warm gear to 150 °C, install gear.

Install output gear retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 237

Install output shaft sealing rings.

Install rear oil baffle on output shaft.

Install oil baffle mounting screws, washer and nuts

and tighten nuts to specified torque (Use Loctite
243).
 Copyright ©

238 SECTION 21 - TRANSMISSION

DISCONNECT SHAFT DISASSEMBLY

Use bearing puller to remove disconnect shaft front
bearing.

Remove front bearing.

Remove front bearing retaining ring.

Remove clutch hub from shaft.

 Copyright ©

SECTION 21 - TRANSMISSION 239

Remove clutch hub locating ring from shaft.

 Copyright ©

240 SECTION 21 - TRANSMISSION

DISCONNECT SHAFT ASSEMBLY

Install bushing if necessary.

Install clutch hub locating ring.

Install clutch hub on shaft.

Install front bearing retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 241

Install front bearing on shaft.

Tap bearing on shaft.

 Copyright ©

242 SECTION 21 - TRANSMISSION

PUMP DRIVE SHAFT DISASSEMBLY

Remove rear bearing snap ring.

Use bearing puller to remove rear bearing.

Remove rear bearing from shaft.

Remove sealing ring from shaft.

 Copyright ©

SECTION 21 - TRANSMISSION 243

PUMP DRIVE SHAFT ASSEMBLY

Install sealing ring on shaft.

Install rear bearing on shaft.

Tap bearing into place.

Install rear bearing retainer ring.

 Copyright ©

244 SECTION 21 - TRANSMISSION

INPUT SHAFT DISASSEMBLY

Remove input shaft rear sealing ring.

Remove forward high gear retaining ring.

Remove forward low gear retaining ring.

Remove input shaft front sealing ring.

 Copyright ©

SECTION 21 - TRANSMISSION 245

Use bearing puller to remove input shaft front

bearing.

Remove input shaft front bearing.

Remove input shaft front bearing retaining ring.

Remove forward low gear retaining ring.

 Copyright ©

246 SECTION 21 - TRANSMISSION

Press forward low gear from shaft.

 Copyright ©

SECTION 21 - TRANSMISSION 247

INPUT SHAFT ASSEMBLY

Install forward low gear retaining ring.

Warm gear to 150 °C, install gear.

Install forward low gear retaining ring.

Install input shaft front bearing retaining ring.

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248 SECTION 21 - TRANSMISSION

Install input shaft front sealing ring.

Warm input shaft front bearing to 120 °C, install

bearing.

Turn shaft and install input shaft forward high gear

retaining ring.

Install input shaft rear sealing ring.

 Copyright ©

SECTION 21 - TRANSMISSION 249

CONVERTER HOUSING ASSEMBLY

Install safety valve ball spring and plug.

Install by-pass valve ball spring and plug.

Install output shaft front oil seal.

Using suitable seal installer, tap seal in place.

 Copyright ©

250 SECTION 21 - TRANSMISSION

Install input shaft into housing and in the meantime

install reverse and first shaft (they have to be
installed together). Using caution as not to damage
any of the first shaft sealing rings.

Install forward low shaft and high shaft into housing.

Using caution as not to damage any sealing rings.

Install disconnect shaft assembly into housing.

Open bearing retaining ring. Tap shaft into place. Be

sure ring is in groove.
 Copyright ©

SECTION 21 - TRANSMISSION 251

Install upper and lower output at the same time.

Do not force this operation, be sure discs of
disconnect are in full position. Using caution as not
to damage any of the lower shaft sealing rings.

Install baffle plate, mounting screws, washers and

nuts. Tighten nuts to specified torque. (Use Loctite
243).

Install baffle plate, mounting screws, washers and

nuts. Tighten nuts to specified torque. (Use Loctite
243).

Install oil baffle, mounting screws and washers.

Tighten screws to specified torque. (Use Loctite
243).
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252 SECTION 21 - TRANSMISSION

Install O-ring, spacer and snap ring on suction tube.

Install suction tube into housing. Be sure ring is in
groove.

Install suction tube retainer, mounting screw and

lock washer (Use Loctite 243).

Tighten mounting screw to specified torque.

Install output shaft rear bearing retaining ring.

 Copyright ©

SECTION 21 - TRANSMISSION 253

Warm forward high gear to 150 °C, install gear.

Warm upper output rear bearing to 120 °C, install

bearing.

Warm reverse and 1st shaft rear bearing to 120 °C,

install bearing.

Warm input shaft rear bearing to 120 °C, install

bearing.
 Copyright ©

254 SECTION 21 - TRANSMISSION

Warm forward low and high shaft rear bearing to

120 °C, install bearing.

Warm lower output shaft rear bearing to 120 °C, in-

stall bearing.

Install output shaft rear bearing retaining ring.

Install gasket and clutch pressure O-rings (4) into O-

ring grooves.
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SECTION 21 - TRANSMISSION 255

TRANSMISSION ASSEMBLY
Remove lower output bore plug. Position transmis-
sion case on converter housing (using lifting brack-
et).

Using spreading type snap ring pliers, spread ears

on output shaft rear bearing retaining ring. Holding
snap ring open. Tap transmission case into place.

Tap dowel pin in transmission case and converter

housing.

Install transmission case to converter housing

mounting screws and lock washers.
Tighten mounting screws to specified torque.
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256 SECTION 21 - TRANSMISSION

Using spreading type snap ring plier, spread ears on

output shaft rear bearing retaining ring. Hold snap
ring open, pry or lift output shaft. Be sure retaining
ring is complete in bearing groove. (Using a lifting
eye or screw M12).

Install hole plug and gasket.

Tighten plug to 13.6 - 20.3 Nm.

Position lower output bore plug and tap bore plug

into place.
 Copyright ©

SECTION 21 - TRANSMISSION 257

Position upper output seal.

Tap seal into place.

Install upper output flange, O-ring, washer and nut

and tighten nut to 339 - 407 Nm.

Install pump drive shaft assembly into housing.

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258 SECTION 21 - TRANSMISSION

Install pump drive shaft rear bearing retaining ring.

Install pump hole cover, gasket, screws and lock

washers.

Tighten pump hole cover screws.

Install pump and O-ring into converter housing.

 Copyright ©

SECTION 21 - TRANSMISSION 259

Install pump mounting screws and lock washers and

tighten screws.

Install converter assembly on input shaft.

Install drive plates on converter.

Install drive plates screws and lock washers and

tighten screws.
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260 SECTION 21 - TRANSMISSION

Install filter adapter, O-ring, lock washers and

mounting screws.

Tighten screws.

Install oil filter and tighten to 30 - 38 Nm.

Instal output shaft front flange, O-ring, washer and

nut. Tighten nut to 339 - 407 Nm.
 Copyright ©

SECTION 21 - TRANSMISSION 261

Position parking brake, install mounting screws (See

parking brake adjustment).

Install by-pass valve spool into solenoid housing and

spring into transmission case, position control valve
on transmission case.

Install control valve mounting screws and lock

washers, tighten screws.

Position wiring connector in valve protection cover.

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262 SECTION 21 - TRANSMISSION

Install gasket and valve protection cover mounting

screws and tighten screws.

Install air breather and tighten to 34 - 41 Nm.

Install wiring connector nut and tighten to 6 - 8 Nm.

 Copyright ©

SECTION 21 - TRANSMISSION 263

Replacement and adjustment of parking brake

19

20
3

19

2 18

1
17
21

15
16
14

12 13

11

10

9
8
7
6
5
4
F27750

Z Loosen two adjustment locking nuts (4 and 5) enough to slide each torque plate (16 and 18) away from disc
far enough to provide clearance to remove old pads assembly and install new ones. (It may be necessary to
remove one or both nuts).
Z Collapse pad retraction spring (21) and remove from brake head assembly.
Z Slide torque plates (16 and 18) away from disc, move pads assembly (17) out of pockets, and remove from
the brake head assembly from the side.
Z Install new pads assembly (17) in each torque plate (16 and 18).
Z Install pad retention spring (21) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both pads assembly (17).
Z Tighten inner adjusting nut (5) until firm contact is made with the disc by the pads. Torque to 11 Nm make
certain lever is in proper operating position for application.
Z Back off inner adjusting nut (5) and check that disc is free to move (total clearance 0.8 - 1.1 mm).
Z Tighten outer locking nut (4) against inner adjusting nut to lock adjustment bolt in place. Torque to 61 - 75 Nm.
 Copyright ©

264 SECTION 21 - TRANSMISSION

2.13 SPECIAL TOOLS

P/N CNH DESCRIPTION

380000676 Lifting tool
 Copyright ©

SECTION 21 - TRANSMISSION 265

2.14 FAULT FINDING

STALL TEST
Use a stall test to identify transmission, converter, or
engine problems.

TRANSMISSION PRESSURE CHECKS

Transmission problems can be isolated by the use
of pressure tests. When the stall test indicates slip-
ping clutches, then measure clutch pack pressure to
determine if the slippage is due to low pressure or
clutch plate friction material failure.
In addition, converter charging pressure and trans-
mission lubrication pressure may also be measured.

MECHANICAL AND ELECTRICAL CHECKS

Prior to checking any part of the system for hydraulic
function (pressure testing), the following mechanical
and electrical checks should be made:
Z Check the parking brake for correct adjustment.
Z Be sure all lever linkage is properly connected and
adjusted in each segment and at all connecting
points.
Z The controls are actuated electrically. Check the
wiring and electrical components.
Z Be sure that all components of the cooling system
are in good condition and operating correctly.
The radiator must be clean to maintain the proper
cooling and operating temperatures for the engine
and transmission. Air clean the radiator, if neces-
sary.
Z The engine must be operating correctly. Be sure
that it is correctly tuned and adjusted to the correct
idle and maximum no-load governed speed speci-
fications.

HYDRAULIC CHECK
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic cir-
cuit for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmis-
sion fluid must be at the correct (full level). All clutch-
es and the converter and its fluid circuit lines must
be fully charged (filled) at all times. See note below.

NOTE: the transmission fluid must be at operating

temperature of 82 - 93 °C to obtain correct fluid level
and pressure readings. Do not attempt to make
these checks with cold oil.

To raise the oil temperature to this specification it is

necessary to either operate (work) the vehicle or run
the engine with converter at “stall”. (Refer to con-
verter stall procedure).

266 SECTION 21 - TRANSMISSION
PROBLEM CAUSE
Low clutch pressure Low oil level
Clutch pressure regulating valve
stuck open
Faulty charging pump
Broken or worn clutch shaft or
piston sealing rings
Low charging pump output Low oil level
Suction filter plugged
Defective charging pump
Overheating Worn oil sealing rings
Worn charging pump
Low oil level
Dirty oil cooler
Restriction in cooler lines
Noisy converter Worn charging pump
Worn or damaged bearings
Lack of power Low engine R.P.M. at converter
stall
See “Overheating” and make
same checks
Copyright ©
ACTION
Fill to proper level.
Clean valve spool and housing.
Replace pump.
Replace sealing rings.
Fill to proper level.
Clean section pump.
Replace pump.
Remove, disassemble, and rebuild
converter assembly.
Replace.
Fill to proper level.
Clean cooler.
Change cooler lines.
Replace.
A complete disassembly will be
necessary to determine what
bearing is faulty.
Tune engine check governor.
Make corrections as explained in
“Overheating”.
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SECTION 21 - TRANSMISSION 267

2.15 FAULT FINDING

Before attempting any fault finding ensure you have

a suitable multimeter for checking component conti-
nuity. When fault finding remember that with an elec-
trical concern it is often a minor fault that may have
occurred and could be as simple as:
Z Poor continuity between connector pins.
Z Condensation in the connectors.
Z Disconnected cables.
Z Damaged or broken wires all of which could result
in a no drive situation but easily remedied when
found and corrected.
It should also be remembered that mechanical prob-
lems could result in fault codes appearing on the F28292

LED display.

INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the T-
LED and N-LED may be blinking in some way as
F N R T N
shown in the table below.

NOTE: that on an open circuit or connection to bat-

tery plus on ON/OFF outputs can only be detected 1 2 3 4 5 6 7 8
while the corresponding output is in the OFF posi-
tion. 1 2 3 4
Also a short to ground is only detected while the out-
put is on.
F28358

T-LED N-LED CONDITION SITUATION

(Orange) (Red)
Off Off Normal operation -
Off On Normal operation - N selected -
Off Blinks Blinks Normal operation - N selected/speed -
too high
On Off Diagnostic mode was activated at power up -
On On Controller in RESET -malfunction Fault
On Blinks Self calibration in progress -
Blinks On Last fault is currently shown on display Fault
Blinks Blinks slower Input fault detected Fault
Blinks Blinks in phase Non critical output fault detected Fault
Blinks Blinks faster Safety critical output fault detected Fault
Blinks fast Blinks out of phase System shutdown - Neutral till power down Fault
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268 SECTION 21 - TRANSMISSION

LED DISPLAYED FAULTS

If a fault is, or there have been (intermittent faults)
present, a detailed fault display can be selected by
placing: the Powershift lever in neutral position and
pressing the kick down button. The indicated fault on
the LED display can then be localized by using the
table below, until power down.

FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups - F N R T N
Group A:

FAULT SUB GROUP A GROUP INDICATION

Input related LED 1 blinks red 1 2 3 4 5 6 7 8
Output related LED 2 blinks red
Other LED3 blinks red

A B
Within each group several faults are possible. The F28359

second LED’s position - Group B, indicates the fault

area, where the colour indicates the fault type.
Typically an open circuit condition is shown using an
orange LED where a short circuit condition is indicat-
ed with a red LED.
Once the fault code has been determined proceed to
fault codes.

FAULT GROUP FAULT GROUP FAULT FAULT CODE

LED (A) LED (B)
None None No fault active -
1 Red 4 Orange Shift lever input fault F1
1 Red 5 Orange Speed sensor open circuit F2
1 Red 5 Red Speed sensor short circuit F3
1 Red 7 Green Battery over voltage F4
2 Red 4 Orange Open circuit on one or both direction outputs F5
2 Red 4 Red Direction output forced to plus - Critical fault F6
2 Red 5 Orange Other output open circuit F7
2 Red 5 Red Red Other output short circuit F8
2 Red 6 Orange Modulation output open circuit F9
2 Red 6 Red Modulation output short circuit F10
3 Red 5 Red Start-up fault - Limp home mode selected F11
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SECTION 21 - TRANSMISSION 269

SHIFT LEVER INPUT FAULT CODE F1

Perform input test

This test is used to verify operation of the shift lever F N R T N
and its inputs. Blinks Slower
Blink
In this mode driving is possible.
Blinks Blinks

NOTE: the gear position indicators on the micro-

1 2 3 4 5 6 7 8
processor top cover are used to display the test in-
formation.
1 2 3 4

F28360

INPUT TEST REQUIREMENTS: Powershift lever to

be in forward position, twist to upshift (keep the shift
lever in this position during power up) and turn the
ignition on, this will place the microprocessor in the
input test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its re-
spective LED (only 2 at the same time).

IMPORTANT: self test modes can only be started

WHILE POWERING UP (ignition on). Leaving the
self test mode is done by switching OFF the power
of the Microprocessor (ignition off).

POWERSHIFT LEVER POSITIONS - WITH UP LED - LED COLOUR - DISPLAYED =

AND DOWNSHIFT SELECTION NUMBER Okay
Neutral 2 RED
Neutral and upshift 3 RED
Neutral and downshift 1 RED
Forward 2 GREEN
Forward and upshift 3 GREEN
Forward and downshift 1 GREEN
Reverse 2 ORANGE
Reverse and upshift 3 ORANGE
Reverse and downshift 1 ORANGE
Operate disconnect button on loader lever 5 (*) (**) GREEN
Operate 4WD switch on instrument panel 6 (*) (**) GREEN
Foot brake test + 4WD 6 (**) GREEN
Foot brake test + 4WD 7 (*) RED
Transmission in automatic mode 7 (*) RED
Temperature and speed sensor: to test disconnect 8 RED
lead on the sensor and short to ground

*= Auto transmission only

**= Auto/Manual override
 Copyright ©

270 SECTION 21 - TRANSMISSION

Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES

Select neutral and push

kick down button:
= LED 1 red
NO Other input fault
= LED 4 orange
YES YES
Input fault: forward/reverse Check through
Replace the Powershift F2, F3, F4 or F11
lever unit
YES
Test with new Powershift
lever unit fitted
 Copyright ©

SECTION 21 - TRANSMISSION 271

SPEED SENSOR / FAULT CODE F2 AND F3

A fault indication on the display is given to warn of
this problem.
F N R T N
If a speed sensor fault is detected the microproces-
Blinks Slower
sor will modify its behaviour in the following areas: Blinks
Blink

Z no upshifts will be allowed above 2nd gear Blinks 5

Z direction change while in F3 or F4: the actual re-
versal is preceded by a downshift sequence until 1 2 3 4 5 6 7 8
2nd gear is obtained.
Z 4WD braking remains operative. 1 2 3 4
NOTE: that the system response in this case is iden-
tical to the response in case of a power supply over- F28361

voltage.

Speed sensor test using the turbine speed dis-

play Turbine Rev/Min LED
0 1 blinks
NOTE: a lamp test is performed prior to the speed
sensor test and monitors all LEDs are operational. 0 - 249 1 on
250 - 499 2 on
SPEED SENSOR TEST REQUIREMENTS: Power-
shift lever to be in reverse position, twist to upshift 500 - 749 3 on
(keep the shift lever in this position during power up) 750 - 999 4 on
turn the ignition on and start the engine.
With engine running return Powershift lever to neu- 1000 - 1249 5 on
tral position and then place lever in forward and twist 1250 - 1499 6 on
to upshift. Increase engine speed and compare with
the table opposite. 1500 - 1749 7 on
1750 - 1999 8 on
IMPORTANT: self test modes can only be started
WHILE POWERING UP (ignition on). Leaving the above 2000 8 blinks
self test mode is done by switching OFF the power
to the Microprocessor (ignition off).

In this mode, driving is possible.

The LED corresponding with the table opposite illu-
minates to indicate the torque converter turbine
speed and increases with engine revs.

NOTE: application of the foot brakes during this test

will reduce the turbine speed to zero.
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272 SECTION 21 - TRANSMISSION

Speed sensor test okay NO Key start ON

YES YES

End T-LED Blinks

NO No input fault
N-LED Blinks Slower
YES

Select neutral and push

kick down button:
= LED 1 red = LED 1 red
NO NO Other input fault
= LED 5 orange (F2) = LED 5 red (F3)
YES YES YES
Check wires from speed sensor CV pin A to Powershift Refer to F1, F4
Repair NO lever unit pin A or CV pin J to pin U, and continuity test. or F11
Does it test OK?

YES
Check speed sensor has it failed
NO

CV15 (A) CV07 (J)

Change lever unit NO
100 Ω
If static is 0.6 - 0.8 V
or 1.3 - 1.5 V
+ 12 V

YES F28371

Replace sensor
If static is not 0.6 - 0.8 V
or 1.3 - 1.5 V

F28370
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SECTION 21 - TRANSMISSION 273

FAULT CODE F4 / BATTERY OVERVOLTAGE (17

VOLTS PLUS)

Over voltage F N R T N
Even power supply levels up to 30V will not damage Blinks Slower

circuit components. Blink

Above a power supply of 17 Vdc: Blinks

Blinks
Group Fault 1 - Fault code 7.
1 2 3 4 5 6 7 8
NOTE: the speed sensor circuit will not operate
when an over voltage is present. 1 2 3 4

F28362

Above a power supply of 24 Vdc:

the analogue signals are not reliable to convert any
more.
Over voltage: when the voltage exceeds 17 Vdc. F N R T N
Action of the Microprocessor:
Z no upshifts above 2nd gear
Z direction change while in Forward 3 or Forward 4:
the actual reversal is preceded by a downshift se- 1 2 3 4 5 6 7 8
quence until 2nd gear is obtained.
1 2 3 4

+ 24 VDC F28363

Z brake switch activation always engages four wheel

drive.

NOTE: voltages below 8 volts D.C the microproces- F N R T N

sor enters the reset mode.

Intermittent power loss

1 2 3 4 5 6 7 8
After power is restored, the microprocessor goes
through the reset mode.
1 2 3 4

- 8 VDC F28364
 Copyright ©

274 SECTION 21 - TRANSMISSION

Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks Slower
YES

Select neutral and push Other input fault

kick down button: NO Check through F1, F2,
1 red - 7 green F3 or F11
YES
Check battery voltage
NO
above 17.7 Volts
YES
Check dual battery connection Disconnect and reconnect
is parallel and okay NO correctly
YES YES
Check alternator output is
Repair or replace NO it correct
YES
 Copyright ©

SECTION 21 - TRANSMISSION 275

FAULT CODE F5 AND F6 / OPEN CIRCUIT

DIRECTION OUTPUTS

Direction selection related outputs (E06-Pin P, F N R T N

E07-Pin N): Blinks Faster

A short to plus is considered as a critical fault. Shorts Blink

to plus usually result in being blocked in either For- Blinks Blinks

ward or Reverse. If both are on simultaneously, the

transmission Behaviour depends on the state of a 1 2 3 4 5 6 7 8
mechanical interlock inside the transmission.
1 2 3 4

F28365

In this case the Microprocessor normally turns on

the pressure modulator (E03-Pin T). This results in
immediate selection of neutral regardless of the ori-
1 2
gin of the fault. Indeed even in case the short to plus B
A
M
is applied externally, this response effectively blocks
C N L
the transmission in neutral. P U
If however at the time the fault was detected a fault D V K
was also present on the pressure modulator, the mi- R T
croprocessor reverts to shutdown mode and re- E S J
mains this way until power is removed. Shutdown F H
G
mode is a state in which power is removed from the
microprocessor outputs by opening the internal re-
dundant shutdown path. F4288

This only helps if the fault was caused by the micro-

processor internally.
Additionally, during program execution, critical vari-
ables are continuously checked for contents integri-
ty.

Gear Shifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected

SHIFT FORWARD REVERSE

DIAGRAM -
SOLENOIDS
1 2 3 4 1 2
reverse/n X X
forward/n
low/high X X X X
1st/2nd X X X
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276 SECTION 21 - TRANSMISSION

During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault. Green= No fault
Red = short circuit NO
found
Yellow = open circuit or short to battery plus
YES YES
Identify component by LED Identify component by LED
1 - Forward solenoid 1 - Forward solenoid
2 - Reverse solenoid 2 - Reverse solenoid
3 - 1/2 Solenoid 3 - 1/2 Solenoid
4 - Forward High/Low Solenoid 4 - Forward Hi/Lo Solenoid
5 - 4WD/RWD Solenoid 5 - 4WD/RWD Solenoid
6 - Direction modulation solenoid 6 - Direction modulation solenoid
7 - Range modulation solenoid 7 - Range modulation solenoid
YES YES
Example: LED 1(red) forward Example: LED 2 (orange)
solenoid output shorted to reverse solenoid output open
ground or a component. circuit or shorted to battery plus
Check component and continuity Check component and continuity
of the cables and connectors of the cables and connectors
output test

Output test
 Copyright ©

SECTION 21 - TRANSMISSION 277

OUTPUT FAULT - STATUS BY LED COLOUR

OUTPUT TEST REQUIREMENTS: Powershift lever
to be in forward position, twist clockwise to downshift
and turn ignition on.
In this mode, driving is not possible, since all micro-
processor outputs remain off until the test mode is
left.
The colour and number of the LED indicates its sta-
tus:

COLOUR STATUS
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)

Output test - Fault by LED Number

The LED numbers correspond to the connector out-

put wires as follows:
Example:
LED 1 = Forward solenoid - colour
Orange = (Output not connected or shorted to bat-
tery plus)

LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 1 2
A
B M
1 E06 Forward solenoid
C N L
2 E07 Reverse solenoid P U
D V K
R T
E S J
F H
G

F4288
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278 SECTION 21 - TRANSMISSION

Key start ON
YES
T-LED Blinks
NO Safety critical output
N-LED Blinks Faster
YES

Select neutral and push Other output fault

kick down button (F5) NO forced to plus (F6) NO
open circuit 2 red - 4 2 red - 4 red
YES YES
All LEDs green Perform output test - fault Other LEDs are
NO NO
and OK found? orange
YES YES YES
Led 1 orange Led 2 orange Proceed to F7, F8,
YES YES F9 or F10
Check forward Check reverse wire
wire to Powershift to Powershift lever
Repair or YES lever is it faulty is it faulty
replace NO YES NO

Check forward solenoid Check reverse solenoid

Repair or YES resistance - is it faulty resistance - is it faulty
replace NO YES NO

Check internal wires in forward Check internal wires in reverse

Repair or YES solenoid is it faulty solenoid is it faulty
replace
NO YES NO

Replace the
Powershift lever unit

F28372
 Copyright ©

SECTION 21 - TRANSMISSION 279

FAULT CODE F7 AND F8 / OUTPUT FAULT -

STATUS BY LED COLOUR
OUTPUT TEST REQUIREMENTS: Powershift lever
to be in forward position, twist clockwise to downshift
F N R T N
Blinks Blinks
and turn ignition on. Blinks
in Phase

In this mode, driving is not possible, since all micro- Blinks 5

processor outputs remain off until the test mode is
left. 1 2 3 4 5 6 7 8
The colour and number of the LED indicates its sta-
tus: 1 2 3 4
COLOUR STATUS
F28367
GREEN Output OK
ORANGE Output not connected
or shorted to battery
plus
RED Output shorted to
ground (or to another
output)

Output test - Fault by LED Number

The LED numbers correspond to the connector out-
put wires as follows:
Example:
LED colour Red and numbered 3 = 1/2 solenoid out-
put shorted to ground.

LED OUTPUT OUTPUT

NUMBER WIRE FUNCTION 4 5
A
B M
3 E04 1/2 Solenoid
C N L
4 E05 Forward Low/High P U
solenoid D V K
R T
5 E09 AWD/RWD E S J
solenoid F H
G
3
F4293
 Copyright ©

280 SECTION 21 - TRANSMISSION

Key start ON
YES
T-LED Blinks
NO Non critical output
N-LED Blinks in phase
fault
YES

Select neutral and push Other output fault

kick down button (F7) NO (F8) short circuit 2 NO
open circuit 2 red - 5 red - 5 red
YES YES
All LEDs green
NO Perform output test - fault found? NO Other LEDs are
and OK
YES YES YES orange
Led 3 orange or red Led 4 orange or red Led 5 orange or red YES
YES YES YES Proceed to
F9 or F10
Check 1/2 Check AWD/RWD
Repair YES solenoid is it faulty solenoid is it faulty
Check Lo/HI
or NO solenoid is it YES NO
replace YES faulty
NO
Check internal and
external wiring of
affected solenoids are
Repair or
replace YES they faulty
NO

Replace the
Powershift lever unit

5
F28373
 Copyright ©

SECTION 21 - TRANSMISSION 281

FAULT CODE F9 AND F10 / DIRECTION

MODULATION OUTPUT SHORT OR OPEN
CIRCUIT
A fault on this output is considered as a problem po- F N R T N
tentially reducing transmission life. Blinks Blinks
in Phase
Blinks
For this reason while a fault is persistent, the allow-
able direction change speed limit is decreased grad-
Blinks 6
ually (10%) each time a direction change was 1 2 3 4 5 6 7 8
inhibited, down to a minimum of 20% of the maxi-
mum allowable shift speed. 1 2 3 4
After a while this can result in severely degraded
performance (only low speed reversals are possi-
ble), but it has the advantage that the driver cannot F28368

be surprised by a sudden performance loss which

could constitute a safety hazard in itself.

Direction Modulation Solenoid (E03) Pin T

The variable Current solenoid for direction modula-

tion is connected to the modulation Common Plus B
A
M
(Pin K) at one side and to (Pin T) at the other side. 1
A programmable current is increased or reduced to C N L
P U
the solenoid controlling the modulating pressure. D V K
No current corresponds to maximum pressure. R T 2
Approximately 1 Amp corresponds with no pressure. E S J
F H
G

F4296
 Copyright ©

282 SECTION 21 - TRANSMISSION

Key start ON
YES
T-LED Blinks
NO No fault
N-LED Blinks in phase
YES
Select neutral and push
Other non
kick down button (F9) 2 (F10)
NO critical output
red - 5 orange 2 red - 6 red NO
fault, F7 or F8
YES YES
All LEDs green Direction modulator Direction modulator
NO
and OK open circuit short circuit
YES YES
Check solenoid Check solenoid
Repair YES resistance - is it faulty resistance - is it faulty
or
NO YES NO
replace

Repair or Check internal and external wiring of the

replace YES direction modulation solenoid is it faulty
NO

Replace the
Powershift lever unit

F28374
 Copyright ©

SECTION 21 - TRANSMISSION 283

FAULT CODE F11 / START UP FAULT LIMP

HOME SELECTED

Internal faults F N R T N
Blinks Slower

At power up a series of integrity checks is done. Blink

If a fault is detected: Blinks

Blinks
Z and the fault prevent operation as a transmission
1 2 3 4 5 6 7 8
controller: the microprocessor locks itself in a reset
state.
Z and controlling the transmission is still possible: the 1 2 3 4
microprocessor reverts to limp home mode.
F28369
Limp Home mode

Defaulted to if an internal problem is detected at

power up.
This model automatically selected at power up if the
integrity tests show that EPROM parameters are cor-
rupt, but the microprocessor can still function as a
transmission controller (other component’s integrity
are intact).
In this mode the user can operate the transmission in
either direction in 1st and 2nd. There are no protec-
tions; all shifts are unmodulated.

Key start ON
YES
T-LED Blinks
NO No input fault
N-LED Blinks slower
YES
Select neutral and push
NO kick down button (F11) Other output fault 2 red - 6 red
3 red - 5 red NO Refer F1, F2, F3 or F4
YES
Replace the
Powershift lever unit
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284 SECTION 21 - TRANSMISSION

FAULTS OTHER F12

NOT IDENTIFIED BY THE LEDS
There may be situations when an individual compo-
nent develops a fault but it is not highlighted by the
LEDs. If a component is in doubt proceed to input
test as follows:

Perform Input test:

This test is used to verify the inputs.

In this mode driving is possible.

NOTE: the gear position indicators on the microproc-

essor top cover are used to display the test informa-
tion.

INPUT TEST REQUIREMENTS: Powershift lever to

be in forward position, twist to upshift and turn the ig-
nition on, this will place the microprocessor in the in-
put test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its respec-
tive LED.

IMPORTANT: selftest modes can only be started

WHILE POWERING UP (ignition on). Leaving the
selftest mode is done by switching OFF the power of
the microprocessor.

CHECKING OF INPUT REQUESTS LED - LED COLOUR -

NUMBER DISPLAYED
Confirm input test is okay (lever forward, neutral, reverse) and in order check as below:
1. Operate disconnect button on loader lever 5 GREEN = OKAY
2. Operate 4WD switch on instrument panel and foot brakes 6 GREEN = OKAY
3. Foot brake test on later models 7 RED = OKAY
4. Temperature and speed sensor: to test disconnect lead on 8 RED = OKAY
the sensor and short to ground
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SECTION 21 - TRANSMISSION 285

F12

Key start ON
YES
Perform input test and
analyse faults if
possible fault found
NO
Possible input switch faults:
4WD - Request
Repair or Brake - Request
replace YES
Declutch - Request
Direction - Request
Speed/Temp sensor

F13

Key start ON
YES
Perform output test and
check range modulation
Repair or LED 7 (wire E08)
replace YES Green = Okay
Orange = Open circuit
Red = Short circuit
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286 SECTION 21 - TRANSMISSION

LIMP HOME LEAD

In the event of a total failure of the microprocessor
such as a serious cab or loom fire the vehicle can be
moved by using the limp home lead to by-pass the
microprocessor.
Tool No - 380000715

Mounted to the left hand side and to the top of the

transmission is the microprocessor loom connector.
Disconnect the damaged loom and connect the limp 1
home lead in its place.

F11834

Connect the plug end into the 12 volt auxiliary socket

or any available 12 volt supply.

F11835

When seated in the cab start the engine and ensur-

ing that all personnel are clear of the machine select
either forward or reverse on the switch and the ma-
chine will move as requested.

NOTE: when using the limp home lead only 2nd

gear (forward or reverse) is selectable no other gear
change or modulation is available.
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 25 - FRONT AXLES

1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3

1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.3 FAULT FINDING.................................................................................................................................. 23
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 25
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 25
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING.................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 80
3.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 84
3.3 FAULT FINDING................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
 Copyright ©

2 SECTION 25 - FRONT AXLES

 Copyright ©

SECTION 25 - FRONT AXLES 3

1. FRONT AXLE 2WD “CARRARO”

1.1 TECHNICAL SPECIFICATIONS

TYPE
Front steering axle, model 26.00

F27349
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4 SECTION 25 - FRONT AXLES

GREASING

Grease specification Akcela Multi-purpose grease 251H-EP

A A

A A
F27350

DESCRIPTION POSITION
Greasing points A
 Copyright ©

SECTION 25 - FRONT AXLES 5

1.2 DISASSEMBLY AND ASSEMBLY

FRONT AND REAR SUPPORTS

1
7
6 2 9
4
5

8
15 3
13
1
11

10

14
12
8

F27351

Disassembly

Remove the rear support (10) from the differential

support.

10

F27352
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6 SECTION 25 - FRONT AXLES

Remove the O-ring (11) from the rear support (10).

NOTE: this is a destructive operation for the O-ring.

11

10
F27353

Remove the bolt (8) with the lube nibble (9).

Remove the bush (12) from the rear support (10).

12
10
8

9
F27354

Remove the bushes (1) from the rear support (10).

1

10

F27355

Remove the bush (13) and the thrust washer (14)

from the differential support only if necessary.

NOTE: it is advisable to heat the bush (13) to make

easy this operation; this is a destructive operation
for the bush. 14
13

F27356
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SECTION 25 - FRONT AXLES 7

Take the front support (2) out from the axle housing
(6).
2
6

F27357

Remove the bolt (8) with the lube nibble (9).

Remove the bush (3) from the front support (2).
1
Remove the bushes (1) from the front support (2).

2
8
3
9

F27358

Remove the bush (4) and the thrust washer (5) from
the axle housing (6) only if necessary. 6 5

NOTE: it is advisable to heat the bush (4) to make

easy this operation; this is a destructive operation
for the bush.
4

F27359

Assembly

Insert the thrust washer (14) into the differential sup-

port.
Heat the bush (13) at 110÷120 °C then assemble it
to the differential support.

NOTE: if necessary assemble the bush (13) with a 14

pad and a hammer. 13

F27356
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8 SECTION 25 - FRONT AXLES

Apply sealant on bushes (1) contact surface.

Assemble the bushes (1) to the rear support (10) 1
with a pad and a hammer.

10

F27355

Assemble the bush (12) in the rear support (10).

SWARNING
Align the bush hole with the bolt (8) hole.

Mount the bolt (8).

12
10
8

F27360

Lubricate with grease a new O-ring (11).

Insert the O-ring (11) in the rear support (10).

11

10
F27353

Insert the rear support (10) on the differential sup-

port.

SWARNING
Do not damage the O-ring when inserting the rear 10
support on the axle housing.

Tighten the bolt (8) to the request torque and tighten

the lube nibble (9). 8

9 F27361
 Copyright ©

SECTION 25 - FRONT AXLES 9

Insert the thrust washer (5) into the front support

seat. 6 5
Heat the bush (4) at 110÷120 °C then assemble it to
the axle housing (6).

NOTE: if necessary assemble the bush (4) with a

pad and a hammer. 4

F27359

Apply sealant on bushes (1) contact surface.

Assemble the bushes (1) to the front support (2) with
a pad and a hammer.
1

F27362

Assemble the bush (3) into the front support (2) with
a suitable driver and a hammer.

SWARNING
Align the bush hole with the bolt (8) hole.
2
8
Assemble the bolt (8). 3

F27363

Insert the front support (2) on the axle housing (6).

Tighten the bolt (8) to the request torque and tighten
the lube nibble (9). 2
6

8
9
F27364
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10 SECTION 25 - FRONT AXLES

STEERING CYLINDER

19
12
11
21 10
17
20

15
18

16 7
14 8 9
6
13
5
4
3

2 1

F27227

Disassembly

Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).

SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3

NOTE: this is a destructive operation for the nut (1). 1

2
F27228

Repeat the whole sequence at the other side.

 Copyright ©

SECTION 25 - FRONT AXLES 11

Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the 11
conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
use a rubber hammer. 4
Remove only parts that need to be overhauled and/ 10
or replaced. 7

3 5
F27229

Remove the cylinder head (15) from the cylinder

body (19) and remove it from the rod (17). 21
Remove the rod (17) from the cylinder body (19). 19
Remove all the seals and O-rings (13, 14, 16, 18, 20
and 21) from the cylinder body (19), the cylinder 16 20
head (15), and the rod (17). 14
13
18
17
15
F27230

Assembly

Assemble new seals and O-rings (13, 14, 16, 18, 20

and 21) on the cylinder head (15), on the rod piston 21
(17) and on the cylinder body (19). 19

16
14 20
13
18
17
15
F27231

Assemble the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).

17
15
19
F27232
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12 SECTION 25 - FRONT AXLES

Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7

17
3 5
F27233

Install the steering cylinder (7) already assembled

on the central body. 6
Assemble and tighten the screws (6) to the request-
ed torque.

F27504

Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be in- 11 12
serted into the swivel housing (8).

NOTE: it is important to unscrew the locknut (11) to

carry out this operation.

Repeat the whole sequence of the mentioned oper-

ations to the other side.

8
F27235

Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1

F27236
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SECTION 25 - FRONT AXLES 13

Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.

F27238
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14 SECTION 25 - FRONT AXLES

WHEEL HUB

19
12
18
11
18
20
21

10
9 17
8
7 16

6
5
4 22
3 15
13 14

2 12

F27365

Disassembly

Unscrew and remove the fastening screws (1) of the

cover (2). Remove the cover (2) and the O-ring (6).
6

F27366
 Copyright ©

SECTION 25 - FRONT AXLES 15

Unscrew and remove the screws (3). Remove the

thrust washer (4).

Remove the wheel hub (7) using levers and a ham-

mer to facilitate the operation.

NOTE: collect the bearing cone (5). 7

F27368

Position the wheel hub (7) on a flat surface and re-

move the seal ring (9) with a lever.

NOTE: destructive operation for the seal ring (9). 7

5
Remove the bearing cups (5) and (8) using a ham-
mer and a suitable drift.
9
Remove the bearing cone (8) from the swivel hous-
ing end, using a suitable extractor. 8

F27255

Unscrew and remove the fastening bolts (12) from

the upper (11) and lower (13) king pin. 12

SWARNING 11 13
Before removing the king pins (11) and (13), secure
the swivel housing (10) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
10
rent safety regulations to guarantee operator’s safe-
ty.

Remove the king pins (11) and (13).

F27370
 Copyright ©

16 SECTION 25 - FRONT AXLES

Remove the swivel housing (10) from the axle

beam.

10

F27371

Remove the thrust washers (16) and (19) with the

bushes (17) and (18). 19

18

17

16
F27372

Assembly

If it has been previously removed, reassemble the

steering stop composed by the screw (15) and the
nut (14).
15
NOTE: do not tighten the nut (14) until the steering 10 14
angle adjustment has been done.

F27373

Insert the thrust washers (16) and (19) and the

bushes (17) and (18). 19

18

17

16
F27372
 Copyright ©

SECTION 25 - FRONT AXLES 17

If ball joints (21) and (22) have been previously re-

moved, reassembly them on the upper king (11) and
the lower king pin (13).

22 21

13 11

F27374

Secure the swivel housing (10) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 10
ring.
Assemble the swivel housing (10) on the axle beam.

F27371

Assemble the king pins, the lower (13) and the up-
per (11), and tighten the retaining screws (12) to the
requested torque.
12

11 13

F27375

Insert both bearing cups (5) and (8) to their wheel

hub (7) housings using the special tool 380002663
under a press or with a hammer.
Insert the seal ring (9) into the wheel hub (7) with the 5 8
special tool 380002227 and a hammer. 9
7
NOTE: do not lubricate the seal ring (9). 7

F27376
 Copyright ©

18 SECTION 25 - FRONT AXLES

Assemble the bearing cone (8) on the swivel hous-

ing (10). 10 7
Assemble the wheel hub (7) on the swivel housing
(10) and insert the bearing cone (5). 8 5

F27377

Assemble the thrust washer (4). Screw the screws

(3).

Assemble a new O-ring (6). Assemble the cover (2)

and screw two screws (1). Tighten the screws (1) to
the requested torque.
6

F27366
 Copyright ©

SECTION 25 - FRONT AXLES 19

TOE-IN / STEERING ANGLE

11
1 2 3 11
3 2 1

5 5

4 4

F27339

Toe-in

Put two equal one-metre-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.

SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
 Copyright ©

20 SECTION 25 - FRONT AXLES

Measure the distance in mm M between the bars

ends with a tapeline.

NOTE: keep the minimum value, swinging the

measurement point.

F27341

Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5

M -05

F27342

If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1

F27343
 Copyright ©

SECTION 25 - FRONT AXLES 21

After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
1 2

F27344

Steering angle adjustment

Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.

F27345

Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.

F27346

Adjust the mechanical steering stop, screwing in or

out the stop bolt (4), locking it with the locknut (5) to
the requested tightening torque.

5 4

F27347
 Copyright ©

22 SECTION 25 - FRONT AXLES

Steer completely towards the other side and repeat

the same operation.

F27348
 Copyright ©

SECTION 25 - FRONT AXLES 23

1.3 FAULT FINDING

PROBLEM CAUSE

1 2 3 4 5 6 7 8 9
Wheel vibration; front tyre resistance; half shaft
breakage
Steering is difficult; vehicle goes straight while it’s
turning
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent noise

1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with
bigger radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both
tyres.

4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.

5. Bent half shaft

Replace half shaft.

6. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.

7. Spoiled or worn out axle parts

Check the bearings conditions, etc.
Replace whenever necessary.

8. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles.
Check assembly of the various parts of the axle.

9. Incorrect use of the product

See the vehicle producer’s instructions once again.
 Copyright ©

24 SECTION 25 - FRONT AXLES

PROBLEM CAUSE ACTION

Axle beam body bent Vehicle overloaded Replace axle beam body.

Vehicle’s accident

Load bump
Worn out or pitted bearings Insufficient lubrication Replace bearings.

Contaminated oil Use correct lubrication, fill up to the

right level and replace at
recommended intervals.

Excessive use

Normal wear out

Oil leakage form gaskets and Prolonged functioning at high Replace the gasket or seal and
seals temperature of the oil matching surface if damaged.

Oil gasket assembled incorrectly Use correct lubrication and replace

at recommended intervals.

Seal lip damaged

Contaminated oil
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.

Beam body bent Check that wheel support is not

worn out or wrongly adjusted.
 Copyright ©

SECTION 25 - FRONT AXLES 25

2. FRONT AXLE 4WD “CARRARO”

2.1 TECHNICAL SPECIFICATIONS

TYPE
Front steering axle, model 26.16

F27203

POWERSHIFT POWERSHUTTLE RATIO

• • 12.8
• • 12.333
 Copyright ©

26 SECTION 25 - FRONT AXLES

LUBRICATION AND GREASING

Differential oil capacity 6.5 litres

Epicyclic reduction gear oil capacity each side 0.7 litres
Oil specification:
use recommended oil enriched in additives Akcela Hy-Tran Ultra
Note: do not use synthetic or vegetable oil without consent of the axle MAT3525
manufacturer
Grease specification Akcela Multi-purpose grease
251H-EP
Differential oil capacity 6.5 litres

F27204

Fill in excess with MU/EP2 grease

Before assembling, grease indicated surface with POLYMER 400 grease

 Copyright ©

SECTION 25 - FRONT AXLES 27

3 5 1 4 5 3

5 2 5

5 4 5
F27205

DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
 Copyright ©

28 SECTION 25 - FRONT AXLES

Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure. 2

SWARNING
Risk of violent oil ejection.

F27206

To drain the oil remove the level plug (1) and the
drain plug (4).

SWARNING
Risk of violent oil ejection.

Drain all oil.

Clean the drain plug (4) and tighten to the requested
torque.

1 4
F27207

Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the plug (1) to the prescribed torque.

1
F27208

Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi- 3
tion [pos.A] and partially unscrew to release possi-
A B
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Remove the plug and drain the oil.

F27209
 Copyright ©

SECTION 25 - FRONT AXLES 29

Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. 3
Tighten the plug (3) to the requested torque.

F27210
 Copyright ©

30 SECTION 25 - FRONT AXLES

TIGHTENING TORQUES

165 Nm

95 Nm 120 Nm 8 Nm 150 Nm 95 Nm 13 Nm

80 Nm 25 Nm 120 Nm 8 Nm 300 Nm 120 Nm 169 Nm

120 Nm

266 Nm 57 Nm

165 Nm

10 Nm 8 Nm 84 Nm 60 Nm 8 Nm 84 Nm
F27211
 Copyright ©

SECTION 25 - FRONT AXLES 31

2.2 DISASSEMBLY AND ASSEMBLY

FRONT AND REAR SUPPORT

21
18
20
15 17
16 19

14
12
9
6 8
3 5 13
11
10
7
4

2
1
F27212

Disassembly

Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).

14

1 2
F27213
 Copyright ©

32 SECTION 25 - FRONT AXLES

Loosen the bolt (4).

Take the rear support (5) out from the differential
support.

4
F27214

Remove the O-ring (6) from the bush (8) in rear sup-
port (5).

NOTE: this is a destructive operation for the O-ring.

5
7
F27215

Remove the bolt (4).

Remove the bush (8) from the rear support (5).

5 8
4

F27216

Remove the bushes (6) from the rear support (5).

6

F27217
 Copyright ©

SECTION 25 - FRONT AXLES 33

Remove the cover (11) from differential support with

a lever.

11

F27218

Remove the seal rings (12) and (13) from the cover
(11). 13
NOTE: destructive operation for the seal rings. 12

11

F27219

Remove the bush (9) and the thrust washer (10)

from differential support only if necessary.

NOTE: it is advisable to heat the bush (9) to make

easy this operation; this is a destructive operation
for the bush. 10
9

F27220

Loosen the bolt (19).

Take the front support (20) out from the axle hous-
ing (15). 20
15

19

F27221
 Copyright ©

34 SECTION 25 - FRONT AXLES

Remove the bolt (19).

Remove the bush (18) from the front support (20). 21
Remove the bushes (21) from front support (20).
20
18

19

F27222

Remove the bush (17) and the thrust washer (16)

from axle housing (15) only if necessary. 15 16

NOTE: it is advisable to heat the bush (17) to make

easy this operation; this is a destructive operation
for the bush.

17

F27223

Assembly

Insert the thrust washer (10) into the differential sup-

port.
Heat the bush (9) at 110÷120 °C then assemble it to
the differential support.
If necessary assemble the bush (9) with a pad and
a hammer. 10
9

F27220

Assemble the seal ring (13) to the cover (11) with

the special tool 380002432 and a hammer. 13
Assemble the new O-ring (12) to the cover (11).
Lubricate the O-ring (12) and the seal ring (13). 12

11

F27219
 Copyright ©

SECTION 25 - FRONT AXLES 35

Assemble the cover (11) to the differential support.

11

F27218

Apply sealant on bushes (6) contact surface.

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.

F27217

Assemble the bush (8) in the rear support (5).

SWARNING
Align the bush hole with the bolt (4) hole.

Assemble the bolt (4).

5 8
4

F27216

Lubricate with grease a new O-ring (7).

Insert the O-ring (7) in the rear support (5).

5
7
F27215
 Copyright ©

36 SECTION 25 - FRONT AXLES

Insert the rear support (5) on the differential support.

SWARNING
Do not damage the O-ring when inserting the rear
support on the central body. 5

Tighten the bolt (4) to the requested torque.

4
F27214

Assemble the flange (2) to the pinion shaft end (14).

Lock the flange (1) with the bolt (2) and nut (3).
Tighten the nut (3) to the requested torque.

14

1 2
F27213

Insert the thrust washer (16) into the front support

seat. 15 16
Heat the bush (17) at 110÷120 °C then assemble it
to the axle housing (15).

NOTE: if necessary assemble the bush (17) with a

pad and a hammer.
17

F27223

Apply sealant on bushes (21) contact surface.

Assemble the bushes (21) into the front support (20) 21
with a pad and a hammer.

20

F27224
 Copyright ©

SECTION 25 - FRONT AXLES 37

Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
20
SWARNING 18
Align the bush hole with the bolt (19) hole.

Assemble the bolt (19).

19

F27225

Insert the front support (20) on the axle beam.

Tighten the bolt (19) to the requested torque.
20

19

F27226
 Copyright ©

38 SECTION 25 - FRONT AXLES

STEERING CYLINDER

19
12
11
21 10
17
20

15
18

16 7
14 8 9
6
13
5
4
3

2 1

F27227

Disassembly

Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).

SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3

NOTE: this is a destructive operation for the nut (1). 1

2
F27228

Repeat the whole sequence at the other side.

 Copyright ©

SECTION 25 - FRONT AXLES 39

Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the 11
conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
use a rubber hammer. 4
Remove only parts that need to be overhauled and/ 10
or replaced. 7

3 5
F27229

Remove the cylinder head (15) from the cylinder

body (19) and remove it from the rod (17). 21
Remove the rod (17) from the cylinder body (19). 19
Remove all the seals and O-rings (13, 14, 16, 18, 20
and 21) from the cylinder body (19), the cylinder 16 20
head (15), and the rod (17). 14
13
18
17
15
F27230

Assembly

Assemble new seals and O-rings (13, 14, 16, 18, 20

and 21) on the cylinder head (15), on the rod piston 21
(17) and on the cylinder body (19). 19

16
14 20
13
18
17
15
F27231

Assemble the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).

17
15
19
F27232
 Copyright ©

40 SECTION 25 - FRONT AXLES

Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7

17
3 5
F27233

Install the steering cylinder (7) already assembled

on the central body. 6
Assemble and tighten the screws (6) to the request-
ed torque.

F27234

Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be in- 11 12
serted into the swivel housing (8).

NOTE: it is important to unscrew the locknut (11) to

carry out this operation.

Repeat the whole sequence of the mentioned oper-

ations to the other side.

8
F27235

Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1

F27236
 Copyright ©

SECTION 25 - FRONT AXLES 41

Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.

F27238
 Copyright ©

42 SECTION 25 - FRONT AXLES

EPICYCLIC REDUCTION GEAR

10
9
8
7
6
5

4
2

1
3
F27239

Disassembly

Drain the oil completely from the planetary carrier.

F27240
 Copyright ©

SECTION 25 - FRONT AXLES 43

Unscrew and remove both fastening screws (3) of

the planetary carrier (1). 3

1
F27241

Remove the planetary carrier (1) from the wheel hub

and collect the relative O-ring (5). 1 5
Position the planetary carrier (1) on a workbench
and check its wear conditions.

F27242

If required replace the planetary gears as follows:

Z remove the snap rings (10) on every pin (4); 7
Z remove the triangular plate (9); 6
Z take the planetary gears (8) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions;
Z collect the thrust washer (6).
10
NOTE: with new planetary gears is advisable to as- 9
sembly new roller bearings. 8
4
F27243

Assembly

Collect all epicyclic reduction gear parts: the plane-

tary carrier (1), the thrust washers (6), the needle 7
bearings (7), the planetary gears (8), the triangular 6
plate (9) and the snap rings (10) of every pin.

NOTE: with new planetary gears is advisable to as-

sembly new roller bearings.
10
9
8
1
F27244
 Copyright ©

44 SECTION 25 - FRONT AXLES

Position the planetary carrier (1) on a workbench.

Insert the thrust washers (6) and the epicyclic gears 9
1 1 10
(8) in the planetary carrier pins.
Insert the needle bearings (7) in the epicyclic gears
(8).

NOTE: grease well the needles.

Assemble the triangular plate (9) and the related

snap rings (10).
6 7 8
F27245

Assemble a new O-ring (5) on the planetary carrier

(1). 1
Assemble the planetary carrier (1) on the wheel hub. 5 1

F27246

Assemble the screws (3) and tighten to the request-

ed torque. 3

1
F27241

Top up the oil on the wheel hub.

Assemble the oil plug (2) on the planetary carrier (1) 2
and tighten to the requested torque.

F27247
 Copyright ©

SECTION 25 - FRONT AXLES 45

WHEEL HUB

28
19

27
18

24

14
22
13
26
12
25
23
11
10
9
8 15
7 21
4 16 20

3 17

2 5 6
F27248

Disassembly

Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to allow the lock ring removal.

SWARNING
Do not damage the double U-Joint.

14
F27249
 Copyright ©

46 SECTION 25 - FRONT AXLES

Remove the lock ring (1) from the double U-Joint

shaft. 3 2
Collect the double U-Joint shaft washers (2) and (3).

F27250

Unscrew and remove the fastening screws (5) from

the wheel carrier (7).
7

F27251

In order to remove the wheel carrier group from its

housing, screw two of the just removed screws (5) 5
in the threaded extraction holes.
Extract and remove the wheel carrier (7) together 7
with the epicyclic ring gear (4).
4

F27253

Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- 6
cial tool 380002223.
7

F27252
 Copyright ©

SECTION 25 - FRONT AXLES 47

Remove the wheel hub (11) using levers and a ham-

mer to facilitate the operation. 15

NOTE: collect the bearing cone (9). 11

F27254

Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a lever.

NOTE: destructive operation for the seal ring (13). 7

5
Remove the bearing cups (9) and (12) using a ham-
mer and a suitable drift.
9
Remove the bearing cone (12) from the swivel hous-
ing end using a suitable extractor. 8

F27255

Unscrew and remove the fastening bolts (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
rent safety regulations to guarantee operator’s safe- 14
ty.

Remove the king pins (16) and (18).

F27256

Remove the swivel housing (14) from the axle beam

and from the short shaft of the double U-Joint.

14

F27257
 Copyright ©

48 SECTION 25 - FRONT AXLES

Remove the spacer (27) from the upper king pin

housing.
27

F27258

Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a lever.

NOTE: destructive operation for the seal ring (23).

22
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.

14 23
F27259

Assembly

If it has been previously removed, reassemble the

steering stop composed by the screw (21) and the
nut (20).

NOTE: do not tighten the nut (20) until the steering

angle adjustment has been done.

20 21

F27260

Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
23 14
press.
Assemble the seal ring (23) on the swivel housing
22
(14) with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).

F27261
 Copyright ©

SECTION 25 - FRONT AXLES 49

Assemble the spacer (27) in the upper king pin

housing.
27

F27258

If the cone (15) of the spherical joint has been pre-

viously removed, reassemble it to the lower king pin
(16) using the special tool 380002662 under a
15
press.
Grease carefully the seats of king pin (16) and (18)
16 28
25
with specific grease.
Position the belleville washers (25) and (28) on the 18 25
king pin (16) and (18) housings.

F27262

Secure the swivel housing (14) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 14
ring.
Assemble the swivel housing (14) on the axle beam.

F27257

Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19

16 18

F27263
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50 SECTION 25 - FRONT AXLES

Assemble both bearing races (9) and (12) to their

wheel hub (11) housings using the special tool
380002663 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002227 and a hammer. 9 12 13
11
NOTE: do not lubricate the seal ring (13). 11

F27264

Assemble the bearing cone (12) on the swivel hous-

ing (14) end. 14
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing cone (9). 12 9

F27265

Position the wheel carrier (7) on a workbench and

force the bushes (6) to the carrier surface level with 6 7
the special tool 380002223.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.

F27266

Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8). 8
7
4

F27267
 Copyright ©

SECTION 25 - FRONT AXLES 51

Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.

F27268

Insert all the hub dowel bushes (6) completely with

the special tool 380002223 and a hammer. 6 5
Apply sealant on fastening bolts (5) thread.
Assemble the wheel carrier (7) fastening bolts (5) 7
and tighten to the requested torque.

F27269

The special operation “Set Right” of the bearings (9)

and (12) does not require preload or backlash ad-
justment. Anyway, before assembling new compo-
nents check the indicated dimensions.

A= 11.975 ÷ 12.025 C A C
B= 52.229 ÷ 52.279
C= 20.000 ÷ 20.100
B

F27270

Insert a lever between the swivel housing and the

axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to make easier the lock ring in-
sertion.

F27271
 Copyright ©

52 SECTION 25 - FRONT AXLES

Slide the thrust washers (2) and (3) onto the double
U-Joint shaft end. 3 2
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.

NOTE: check that the lock ring (1) is correctly fitted

1
in its seat.

Push the double U-Joint thoroughly.

F27250
 Copyright ©

SECTION 25 - FRONT AXLES 53

DOUBLE U-JOINTS

1 2

4
5
6

F27272

Disassembly

Remove the two double U-Joints (6) from the axle

beam (1).

1
6

F27273
 Copyright ©

54 SECTION 25 - FRONT AXLES

Remove the seal rings (5) from the axle beam (1).

NOTE: destructive operation for the seal rings (5).

4
Remove the bush (4) from the axle beam (1) only if 5
the wear conditions require this.

SWARNING
Be careful not to damage the bush seat.

5
F27274

Remove the upper king pin bush (2) and the ball
bearing cup (3) from the king pin seats using a suit-
able extractor only if the wear conditions require
this.

F27275

Assembly

Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C with liq-
uid nitrogen.
2
SWARNING
Wear safety gloves.

Assemble the bush (2) on the upper king pin seat

with the special tool 380002664 and a hammer. 3
Assemble the ball bearing cup (3) on the lower king pin
seat with the special tool 380002662 and a hammer.
F27276

Assemble the bush (4) on the axle beam (1) with the
special tool 380002665 and a hammer.
Assemble the seal ring (5) on the axle beam with the
1
special tool 380002666 and a hammer.
4
NOTE: grease carefully the seal rings. 5

F27277
 Copyright ©

SECTION 25 - FRONT AXLES 55

Assemble the seal ring (5).

SWARNING 5
Positioning the seal ring (5) as in figure.

F27278

Insert the double U-Joint (6) inside the axle beam

(1).

SWARNING
Be careful not to damage the seal ring.

1
6

F27273
 Copyright ©

56 SECTION 25 - FRONT AXLES

DIFFERENTIAL SUPPORT

9 8 13
12
11
10

7
6
14

8
5
4
2 3
1
F27282

Disassembly

Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
14
SWARNING
Support the differential support with a rope or other 2
appropriate means.
1
F27283
 Copyright ©

SECTION 25 - FRONT AXLES 57

Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9 9

8 8

F27284

Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3

F27285

Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.

F27286

Remove the 4 screws (12) and remove both half-

collars (11).

NOTE: check that the bushes (10) remains in their 12

housings.
11

10

F27287
 Copyright ©

58 SECTION 25 - FRONT AXLES

Remove the differential housing (5).

The bearing cones (4) and (6) are removed together
with the differential housing.
4
SWARNING 6
Do not invert the bearing cone if the bearings are not
5
replaced.

F27288

Assembly

Assemble the bearings cone (4) and (6) on the dif-

ferential housing (5).

SWARNING
Do not invert the bearing cones if the bearings are
not replaced. 4

6
5

F27289

Position the complete differential box with bearings

on the differential carrier.

SWARNING
Check the right side of the bevel crown assembly.

F27290

Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both collars with their fastening bolts (12).
11

10

F27291
 Copyright ©

SECTION 25 - FRONT AXLES 59

Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded. 3
Check that the differential bearings are well settled; 7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.

F27292

Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.

F27293

Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, meas-
ured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27294

Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.

F27295
 Copyright ©

60 SECTION 25 - FRONT AXLES

Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.

F27293

Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.

SWARNING F27296

All preloadings must be measured without seal ring.

If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. F27297
 Copyright ©

SECTION 25 - FRONT AXLES 61

Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8

F27298

Tighten the bolts (12) of both half collars (11) to the

requested torque.

12

13

F27299

Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap- 13
propriate detergents.
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier. 14
NOTE: check that two dowel pins (13) are in their 13
housing.

F27300

Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
14

F27301
 Copyright ©

62 SECTION 25 - FRONT AXLES

Bevel gear marking test

To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.

F27302

OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303

Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.

1
F27304
 Copyright ©

SECTION 25 - FRONT AXLES 63

DIFFERENTIAL GROUP

Disassembly

Use an extractor to remove bearing (12) from bevel

pinion.

12

F27306
 Copyright ©

64 SECTION 25 - FRONT AXLES

Use an extractor to remove bearing (12) from bevel

pinion.

F27307

Unscrew all fastening screws (1) of bevel gear

crown (11). 11

SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.

F27308

Remove bevel gear crown (11) by means of a mal-

let.

11

F27309

Check marking points (3) and (10) that will be useful

during the assemblage.
10

F27310
 Copyright ©

SECTION 25 - FRONT AXLES 65

Disassemble the two differential half housings (3)

and (10).
Disassemble all the components.
Check the operating and wear conditions of the
components.

Assembly

Position a half housing (3) on a workbench and as-

semble all inner components: locking differential
counterdisc (4), sun gears (5), spider (9), spider
gear (7), thrust washer (6), pin (8).

Assemble the two half housings of differential unit

(3) and (10).
10
SWARNING
Carefully check that the marks of both differential
half boxes coincide.

F27310

Assemble bevel gear crown (11) by using a ham-

mer.
11

F27314
 Copyright ©

66 SECTION 25 - FRONT AXLES

Apply Loctite 242 on thread of screws (1).

1
F27316

Tighten screws (1) to the requested torque.

NOTE: fix differential housing in the vice.

F27315

Press bearing (12) or assemble after preheating.

12

F27317

Press bearing (2).

F27318
 Copyright ©

SECTION 25 - FRONT AXLES 67

PINION GROUP

Disassembly

Position the differential carrier in a vise.

Unscrew the locknut (10) using special tool
380002218.

NOTE: this operation will irretrievably damage the

locknut (10).

10

F27320
 Copyright ©

68 SECTION 25 - FRONT AXLES

Remove the ring nut (10) and collect its retaining

washer (9).

9
10

F27321

Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8

SWARNING
Take care not to lower the bevel pinion (1). 5
1
Collect the washers (4) and (6), the collapsible
spacer (5) and the bearing cone (8).

6
4
F27322

Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and
a hammer. 3

8
F27326

To remove the bearing cone (3) of the bevel pinion

(1), use a standard extractor.
Collect the bearing cone (3) and the underlying shim
(2). 3

F27324
 Copyright ©

SECTION 25 - FRONT AXLES 69

Check all pinion components for wear.

SWARNING
The ring nut (10) and the collapsible spacer (5) must 5
be replaced when reassembling the unit.
10

F27325

Assembly

Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8) using the special
drifts and a hammer. 3

8
F27326

Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.

F27327

Insert the bearing cones (3) and (8) in their hous-

ings.
Assemble the “false pinion” 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated. 8

10
F27328
 Copyright ©

70 SECTION 25 - FRONT AXLES

Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
7

F27329

Assembly diagram of the “false differential box”

tools 380000407 + 380000440 on the bearing differ-
ential support seats. X
Use a depth gauge to measure distance “X” (dis-
tance between the axis of the differential bearings
and the point at which the pinion head is supported, X
or base of the bearing).

F27330

In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).

S = X-V mm
V

F27331

Select the shim (2) of thickness value (S) among the

range of available shims.

F27332
 Copyright ©

SECTION 25 - FRONT AXLES 71

Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing cones (3) and (8).
8

10
F27328

Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool 380002224 under a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new collapsible
spacer (5).
1 1
NOTE: use always a new collapsible spacer (5).

F27334

Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing cone (8) into 8
the pinion shaft, as shown in figure.
In order to force the bearing (8) into position, use the
special tool and a hammer.
7
It is advisable to offer resistance, for example a
sledge, to the beating force. 1

F27335

Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.

9
10

F27321
 Copyright ©

72 SECTION 25 - FRONT AXLES

Screw the ring nut (10) in, using the wrench

380002218 for ring nut and for pinion retainer.

SWARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10

NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27336

to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.

Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.

P = 9.2÷13.7 daN

SWARNING
All preloadings must be measured without the seal
ring. F27337

Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.

F27338
 Copyright ©

SECTION 25 - FRONT AXLES 73

TOE-IN / STEERING ANGLE

11
1 2 3 11
3 2 1

5 5

4 4

F27339

Toe-in

Put two equal one-metre-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.

SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
 Copyright ©

74 SECTION 25 - FRONT AXLES

Measure the distance in mm M between the bars

ends with a tapeline.

NOTE: keep the minimum value, swinging the

measurement point.

F27341

Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5

M -05

F27342

If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1

F27343
 Copyright ©

SECTION 25 - FRONT AXLES 75

After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
1 2

F27344

Steering angle adjustment

Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.

F27345

Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.

F27346

Adjust the mechanical steering stop, screwing in or

out the stop bolt (4), locking it with the locknut (5) to
the requested tightening torque.

5 4

F27347
 Copyright ©

76 SECTION 25 - FRONT AXLES

Steer completely towards the other side and repeat

the same operation.

F27348
 Copyright ©

SECTION 25 - FRONT AXLES 77

2.3 FAULT FINDING

PROBLEM CAUSE

1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise

1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with
bigger radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both
tyres.

4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.

5. Bent half shaft

Replace half shaft.

6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.

7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.

8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings etc.
Replace whenever necessary.

9. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.

10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.

11. Incorrect use of the product

See the vehicle producer’s instructions once again.

78
PROBLEM
Ring gear tooth broken on the
outer side
Ring gear tooth broken side
Pinion or ring gear teeth worn
Overheated ring and pinion teeth
See if gear teeth have faded
Pinion teeth pitting
Axle beam body bent
Worn out or pitted bearings
Oil leakage form gaskets and
seals
Excessive wearing out of input
flange spline
Fatigue failure of pinion teeth
See if the fracture line is well
defined
(wave lines, beach lines)
Pinion and ring teeth breakage
SECTION 25 - FRONT AXLES
CAUSE
Excessive gear load compared to
the one foreseen
Incorrect gear adjustment
(excessive backlash)
Pinion nut loose
Load bump
Incorrect gear adjustment
(insufficient backlash)
Pinion nut loose
Insufficient lubrication
Contaminated oil
Incorrect lubrication or depleted
additives
Worn out pinion bearings that
cause an incorrect pinion axle
backlash and wrong contact
between pinion and ring
Prolonged functioning at high
temperatures
Incorrect lubrication
Low oil level
Contaminated oil
Excessive use
Insufficient lubrication
Vehicle overloaded
Vehicle’s accident
Load bump
Insufficient lubrication
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Prolonged functioning at high
temperature of the oil
Oil gasket assembled incorrectly
Seal lip damaged
Contaminated oil
Exhaustive use
Pinion nut loose
Pinion axle backlash
Exhaustive use
Continuous overload
Crash load of differential
components
Copyright ©
ACTION
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Use correct lubricants, fill up to the
right levels and replace according to
the recommended program.
Replace bevel gear set.
Use proper lubrication, fill up to right
level and replace at recommended
program.
Replace bevel gear set.
Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Replace axle beam body.
Replace bearings.
Use correct lubrication, fill up to the
right level and replace at
recommended intervals.
Replace the gasket or seal and
matching surface if damaged.
Use correct lubrication and replace
at recommended intervals.
Replace the flange.
Check that the pinion spline is not
excessively worn out.
Replace bevel gear set if required.
Replace bevel gear set.
Check and/or replace other
differential components.

Side gear spline worn out
Replace all scratched washers
(Excessive backlash)
Thrust washer surface worn out
or scratched
Inner diameter of tapered roller
bearing worn out
Bent or broken half shaft
Half shaft broken at wheel side
SECTION 25 - FRONT AXLES
Excessive use
Insufficient lubrication
Incorrect lubrication
Contaminated oil
Excessive use
Excessive pinion axial backlash
Insufficient lubrication
Contaminated oil
Vehicle intensively operated or
overloaded
Wheel support loose
Beam body bent
Copyright ©
79
Replace differential gear group.
Replace half shaft if required.
Use correct lubrication and fill up to
right level.
Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Replace bearing.
Check pinion axial backlash.
Use proper lubrication, fill up to right
level and replace at recommended
intervals.
Replace.
Replace.
Check that wheel support is not
worn out or wrongly adjusted.
 Copyright ©

80 SECTION 25 - FRONT AXLES

3. FRONT AXLE 4WS “CARRARO”

3.1 TECHNICAL SPECIFICATIONS

TYPE
Front steering axle, model 26.28

F27378

POWERSHIFT SELF LOCKING RATIO

• / 18.46
• • 18.46
 Copyright ©

SECTION 25 - FRONT AXLES 81

LUBRICATION AND GREASING

Oil capacity 11.0 litres

Oil specification:
use recommended oil enriched in additives
Akcela Nexplore MAT3525
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
Grease specification Akcela Multi-purpose grease
251H-EP

1 4
3 5 5 3

5 2 5

5 5
F27379

DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
 Copyright ©

82 SECTION 25 - FRONT AXLES

Before draining the oil from axle housing, use the

breather (2) to release possible internal pressure. 2

SWARNING
Risk of violent oil ejection.

F27206

To drain the oil remove the level plug (1) and the
drain plug (4).

SWARNING
Risk of violent oil ejection.

Drain all oil.

Clean the drain plug (4) and tighten to the requested
torque.

1 4
F27207

Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the level plug (1) to the prescribed torque.

1
F27208

Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi- 3
tion [pos.A] and partially unscrew to release possi-
A B
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Remove the plug and drain the oil.

F27209
 Copyright ©

SECTION 25 - FRONT AXLES 83

Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. 3
Tighten the plug (3) to the requested torque.

F27210
 Copyright ©

84 SECTION 25 - FRONT AXLES

3.2 DISASSEMBLY AND ASSEMBLY

FRONT AND REAR SUPPORT

21
18
22
17
15 16

19

23

7
6
8
5
11

1 14
3 10
4

9
12
13
2 F27380

Disassembly

Remove the nut (3) and the bolt (2) and extract the
flange (1).

1
3

2
F27381
 Copyright ©

SECTION 25 - FRONT AXLES 85

Remove oil seal (13).

13

F27382

Unscrew the screws (11) and remove the flange

(12).

12
11

F27383

Loosen the fastening screw (4).

Take the rear support (5) out from the differential
support.

4
F27384

Remove the O-ring (6) from the bush in rear support

(5).

NOTE: this is a destructive operation for the O-ring

(7).

5
F27385
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86 SECTION 25 - FRONT AXLES

Remove the bolt (4) and the lube nibble (9).

Remove the bush (8) from the rear support (5).

8
5
4

9
F27386

Remove the bushes (6) from rear support (5).

6

F27217

Remove the washer (10) from differential support

only if necessary.

10

F27387

Loosen the fastening screw (19).

Take the front support (20) out from the axle hous- 20
ing (15). 15

19

F27388
 Copyright ©

SECTION 25 - FRONT AXLES 87

Remove O-ring (22).

Remove the bolt (19) and lube nibble (23). 21
Remove the bush (18) from the front support (20).
Remove the bushes (21) from front support (20).

20
19
18
23
22

F27389

Remove the bush (17) and washer (16) from axle

housing (15) only if necessary. 17
15
NOTE: it is advisable to heat the bush (17) to make
easy this operation; this is a destructive operation
for the bush.
16

F27390

Assembly

Insert the washer (10) into the differential support.

10

F27387

Apply sealant on bushes (6) contact surface.

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.

F27217
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88 SECTION 25 - FRONT AXLES

Assemble the bush (8) in the rear support (5).

SWARNING
Align the bush hole with the bolt (4) hole.

Assemble the bolt (4).

5 8
4

F27216

Lubricate with grease a new O-ring (7).

Insert the O-ring (7) in the rear support (5).

5
7
F27215

Insert the rear support (5) on the differential support.

SWARNING
Do not damage the O-ring when inserting the rear 5
support on the central body.

Tighten the bolt (4) to the requested torque.

Assemble the lube nibble (9).
4

9
F27391

Insert the washer (16) into the front support seat.

Heat the bush (17) at 110÷120 °C then assemble it 17
to the axle housing (20). 15
NOTE: if necessary assemble the bush (17) with a
pad and a hammer.
16

F27390
 Copyright ©

SECTION 25 - FRONT AXLES 89

Apply sealant on bushes (21) contact surface.

Assemble the bushes (21) to the front support (20) 21
with a pad and a hammer.

20

F27224

Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.

SWARNING 20
Align the bush hole with the bolt (19) hole. 19
18
Mount the bolt (19). 22
Assemble O-ring (22).

F27393

Insert the front support (20) on the axle beam.

Tighten the bolt (19) to the requested torque. 20
Assemble the lube nibble (23).
19

23

F27394

Assemble the flange (12) and fasten by tightening

the screws (11).

12
11

F27383
 Copyright ©

90 SECTION 25 - FRONT AXLES

Assemble seal ring (13) use special tool

380002225.

13

F27382

Assemble the flange (2) to the pinion shaft end.

Lock the flange (1) with the bolt (2) and the nut (3).
Tighten the nut (3) to the requested torque.

1
3

2
F27381
 Copyright ©

SECTION 25 - FRONT AXLES 91

STEERING CYLINDER

24
23
22
10
21
9
13 20
8
19
14 18
7
6
5
4
3

17 12
16 11
15

1
F27396

Disassembly

Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).

SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3

NOTE: this is a destructive operation for the nut (1). 1

2
F27228

Repeat the whole sequence at the other side.

 Copyright ©

92 SECTION 25 - FRONT AXLES

Remove the tie rods (3) and (10) by loosing the nuts
(4) and (9) with a suitable wrench, then check the 13
13
conditions.
Unscrew the fastening screws (13) and take the 10
14
steering cylinder (7). 9
Remove only parts that need to be overhauled and/ 8
15
or replaced. 7
6
5
4
3
F27397

Remove the cylinder head (18) from the cylinder

body (22) and remove it from the rod (20). 23
Remove the rod (20) from the cylinder body (22). 20
Remove all the seals and O-rings (16, 17, 19, 21, 23
and 24) from the cylinder body (22), the cylinder 24
head (18), and the rod (20). 22
17
16 21

19
18 F27398

Assembly

Assemble new seals and O-rings (16, 17, 19, 21, 23

and 24) on the cylinder head (18), on the rod piston 23
(20) and on the cylinder body (22).

24
17 22
16 21
20
19
18
F27392

Assemble the cylinder head (18) on the rod (20).

Slide the pre-assembled rod (20) into the cylinder
body (22).

22

20

18
F27399
 Copyright ©

SECTION 25 - FRONT AXLES 93

Assemble the tie rods (3) and (8), the ball joints (3)
and (10), the nuts (4) and (9) to the ends of the rod,
then tighten with a dynamometric wrench to the re-
quested torque. 10
9
8
7
6
5
4
3
F27400

Install the steering cylinder (7) already assembled

on the central body.
Assemble and tighten the screws (13) with dynamo-
metric wrench to the requested torque.
Assemble bracket (14).

Align the swivel housing (11) with the axle.

Screw the tie rod (10) so that its ball joint can be in- 9 10
serted into the swivel housing (11) arm.

NOTE: it is important to unscrew the locknut (9) to

carry out this operation.

Repeat the whole sequence of the mentioned oper-

ations to the other side.

11
F27402

Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1

F27236
 Copyright ©

94 SECTION 25 - FRONT AXLES

Screw the locknuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been car- 4 9 3 10
ried out.

F29526
 Copyright ©

SECTION 25 - FRONT AXLES 95

EPICYCLIC REDUCTION GEAR

11
9
10
8
7
6
5

1
3
2

F27404

Disassembly

Drain the oil completely from the planetary carrier.

F27240
 Copyright ©

96 SECTION 25 - FRONT AXLES

Unscrew and remove both fastening screws (3) of

the planetary carrier (1). 3

1
F27241

Remove the planetary carrier (1) from the wheel

hub.
Position the planetary carrier (1) on a workbench
and check its wear conditions.

F27405

If required replace the planetary gears as follows:

Z unscrew screws (11) on every pin (4); 4 10
Z remove washer (9) and washer (8);
Z take the planetary gears (7) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions; 11
Z collect the washer (6). 9
8
NOTE: with new planetary gears is advisable to as- 7
sembly new roller bearings. 6
5
F27406

Assembly

Position the planetary carrier (1) on a workbench.

Insert in the pins of the planetary gears carrier the 1 10
washers (5) and the planetary gears (7) complete
with rollers (6).
Assemble the bearing cups (8) and fasten them with
the pins (10). 11
Fit the washers (9) and screw in the screws (11) by 9
tightening them at the prescribed torque. 8
7
NOTE: with new planetary gears it is advisable to 6
assembly new roller bearings. 5
F29008
 Copyright ©

SECTION 25 - FRONT AXLES 97

Assemble the epicyclic reduction gear (1) on the

wheel hub.

F27405

Assemble the screws (3) and tighten to the request-

ed torque. 3

F27407

Top up the oil on the wheel hub.

Fit the filling/drain and level oil plug (2) on the plan- 2
etary carrier (1) and tighten to the requested torque.

F27408
 Copyright ©

98 SECTION 25 - FRONT AXLES

WHEEL HUB

19

26
18

24
27

14
22
13
12
25
11 23
10
9
8 15
7 21
4 16 20

3 17

2 5 6
F27409

Disassembly

Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to allow the lock ring removal.

SWARNING
Do not damage the double U-Joint.

14
F27410
 Copyright ©

SECTION 25 - FRONT AXLES 99

Remove the lock ring (1) from the double U-Joint

shaft. 3 2
Collect the double U-Joint shaft washers (2) and (3).

F27250

Unscrew and remove the fastening screws (5) from

the wheel carrier (7).
7

F27251

In order to remove the wheel carrier group from its

housing, screw two of the just removed screws (5) 5
in the threaded extraction holes.
Extract and remove the wheel carrier (7) together 7
with the epicyclic ring gear (4).
4

F27253

Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- 6
cial tool 380002667.
7

F27252
 Copyright ©

100 SECTION 25 - FRONT AXLES

Remove the wheel hub (11) using levers and a ham-

mer to facilitate the operation. 15

NOTE: collect the bearing cone (9). 11

F27254

Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a lever. 13
12
NOTE: destructive operation for the seal ring (13). 11
Remove the bearing cups (9) and (12) using a ham- 10
mer and a suitable drift. 9
Remove the bearing cone (12) from the swivel hous-
ing end using a suitable extractor.

F27412

Unscrew and remove the fastening bolts (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
rent safety regulations to guarantee operator’s safe- 14
ty.

Remove the king pins (16) and (18).

F27256

Remove the swivel housing (14) from the axle beam

and from the short shaft of the double U-Joint.

14

F27257
 Copyright ©

SECTION 25 - FRONT AXLES 101

Collect the belleville washers (25) and (26).

26

25
F27413

Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a lever.

NOTE: this is a destructive operation for the seal

ring. 22

Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.

14 23
F27259

Assembly

If it has been previously removed, reassemble the

steering stop composed by the screw (21) and nut
(20).

NOTE: do not tighten the nut (20) until the steering

angle adjustment has been done.

20 21

F27260

Assemble the bush into the swivel housing (14) with

the special tool 380002668 and a hammer or a
23 14
press.
Assemble the seal ring (23) on the swivel housing
22
(14) with the special tool 380002669 and a hammer.
Grease carefully the seal ring (23).

F27261
 Copyright ©

102 SECTION 25 - FRONT AXLES

If ball joints (15) and (27) have been previously re-

moved, reassembly them on the lower (16) and up-
per king pin (18).
Grease well the king pin housings (16) and (18) with 27 15
specific grease. 26
Position the Belleville washers (25) and (28) on the 18 16
king pin housings. 25

F27414

Secure the swivel housing (14) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 14
ring.

F27257

Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19

16 18

F27263

Assemble both bearing races (9) and (12) to their

wheel hub (11) housings using the special tool
380002222 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002213 and a hammer. 13 9 12

NOTE: do not lubricate the seal ring (13). 11 11

F27525
 Copyright ©

SECTION 25 - FRONT AXLES 103

Assemble the bearing cone (12) on the swivel hous-

ing (14). 14
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing cone (9). 12 9

F27265

Position the wheel carrier (7) on a workbench and

force the bushes (6) to the carrier surface level with 6 7
the special tool 380002667.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.

F27266

Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8). 8
7
4

F27267

Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.

F27268
 Copyright ©

104 SECTION 25 - FRONT AXLES

Force all the hub dowel bushes (6) completely with

the special tool 380002667 and a hammer. 6 5
Apply sealant on fastening bolts (5) thread.
Assemble the wheel carrier (7) fastening bolts (5) 7
and tighten to the requested torque.

F27269

Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to make easier the lock ring in-
sertion.

14
F27410

Assemble the thrust washers (2) and (3) onto the

double U-Joint shaft end.
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.

NOTE: check that the lock ring (1) is correctly fitted

in its seat.

3 2 1
F27416
 Copyright ©

SECTION 25 - FRONT AXLES 105

DOUBLE U-JOINTS

1
2
3
4

F27417

Disassembly

Remove the two double U-Joints (4) from the axle

beam (1).

1
4

F27418
 Copyright ©

106 SECTION 25 - FRONT AXLES

Remove the seal rings (3) from the axle beam (1).
1
NOTE: destructive operation for the seal rings (3). 2
3
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.

SWARNING
Be careful not to damage the bush seat.

3
F27419

Assembly

Assemble the bush (2) on the axle beam (1) with the
special tool 380002226 and a hammer.
Assemble the seal ring (3) on the axle beam with the
1
special tool 380002670 and a hammer.
2
NOTE: grease carefully the seal rings. 3

F27420

Assemble the seal ring (3) as in figure.

F27421

Insert the double U-Joint (4) inside the axle beam

(1).

SWARNING
Be careful not to damage the seal ring.

1
6

F27273
 Copyright ©

SECTION 25 - FRONT AXLES 107

DIFFERENTIAL SUPPORT GROUP

9 8 13
12
11
10

7
6
14

8
5
4
2 3
1
F27411

Disassembly

Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).

SWARNING
Support the differential support with a rope or other
appropriate means.
2
14
1
F27501
 Copyright ©

108 SECTION 25 - FRONT AXLES

Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9
9

8
8

F27395

Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3

F27422

Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.

F27423

Remove the 4 screws (12) and remove both half-

collars (11).

NOTE: check that the bushes (10) remains in their 12

housings.
11

10

F27424
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SECTION 25 - FRONT AXLES 109

Remove the differential housing (5).

The bearing cones (4) and (6) are removed together
with the differential housing.
4
SWARNING 6
Do not invert the bearing cone if the bearings are not 5
replaced.

F27425

Assembly

Assemble the bearings cone (4) and (6) on the dif-

ferential housing (5).

SWARNING
Do not invert the bearing cones if the bearings are
not replaced. 4

6
5

F27289

Position the complete differential box with bearings

on the differential carrier.

SWARNING
Check the right side of the bevel crown assembly.

F27427

Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both collars with their fastening bolts (12). 11

10

F27428
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110 SECTION 25 - FRONT AXLES

Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled; 3
7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.

F27429

Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.

F27293

Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, meas-
ured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27430

Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.

F27295
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SECTION 25 - FRONT AXLES 111

Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.

F27431

Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.

SWARNING F27432

All preloadings must be measured without seal ring.

If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. F27297
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112 SECTION 25 - FRONT AXLES

Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8

F27298

Tighten the bolts (12) of both half collars (11) to the

requested torque.

12

11

F27434

Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap-
propriate detergents. 13
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier
(1).

NOTE: check that two dowel pins (13) are in their

housing.

14
F27435

Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.

2
14
1
F27501
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SECTION 25 - FRONT AXLES 113

Bevel gear marking test

To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.

F27302

OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303

Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.

1
F27304
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114 SECTION 25 - FRONT AXLES

DIFFERENTIAL GROUP (STANDARD)

8
1

11
10
9
13
12
7
6
8
7
6
5
4
3
2
F27437

Disassembly

Use an extractor to remove bearing (10) from bevel

pinion.

10

F27438
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SECTION 25 - FRONT AXLES 115

Use an extractor to remove bearing (2) from bevel

pinion.

F27307

Unscrew all fastening screws (1) of bevel gear

crown (11). 11

SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.

F27308

Remove the bevel gear crown (11) by means of a

mallet.

11

F27309

Check marking points (3) and (9) that will be useful

during the assemblage.
9

F27439
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116 SECTION 25 - FRONT AXLES

Remove planetary gear (5) and shim (4).

4

F27440

Remove differential pin (8), planetary gear (7) and

spheric washer (6).

6 6

7 7

F27441

Remove planetary gear (12) and shim (13).

12

13

F27442

Assembly

Apply a thin layer of Molicote G-n plus paste on half

housing of differential (3) and (9). 3 9

SWARNING
Remove rests of dope.

F27443
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SECTION 25 - FRONT AXLES 117

Apply a thin layer of Molicote G-n plus paste on

planetary gears (5), (12), and on planetary gears 7
(7).

12

F27444

Assemble planetary gear (12) with shim (13).

12

13

F27442

Assemble the differential unit pin (8) and planetary

gears (7) and washers (6).

6 6

7 7

F27441

Assemble planetary gear (5) with shim (4).

4

F27440
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118 SECTION 25 - FRONT AXLES

Assemble the two half housings of differential unit

(3) and (9).
9
SWARNING
Carefully check that the marks of both differential
half boxes coincide.

F27439

Assemble the bevel gear crown (11) by using a

hammer.
11

F27314

Apply Loctite 242 on thread of screws (1).

1
F27316

Tighten screws (1) to the requested torque.

NOTE: fix differential housing in the vice.

F27315
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SECTION 25 - FRONT AXLES 119

Press bearing (10) or assemble after preheating.

10

F29010

Press bearing (2).

F27318
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120 SECTION 25 - FRONT AXLES

DIFFERENTIAL GROUP (SELF-LOCKING)

14
10
13
8
12
9
5
1
4
6
11
10
8
9
7
6
5
4
3
2
F27448

Disassembly

Use an extractor to remove bearing (13) from bevel

pinion.

13

F27449
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SECTION 25 - FRONT AXLES 121

Use an extractor to remove bearing (2) from bevel

pinion.

F27307

Unscrew all fastening screws (1) of bevel gear

crown (14). 14

SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.

F27446

Remove bevel gear crown (14) by means of a mal-

let.

14

F27450

Check marking points (3) and (12) that will be useful

during the assemblage.
12

F27451
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122 SECTION 25 - FRONT AXLES

Remove discs (4) and (5).

4 5

F27452

Remove planetary gear (11).

11

F27453

Remove differential pin (10), planetary gear (8) and

spheric washers (9).

9 9

8 8

10

F27454

Remove planetary gear (7).

F27455
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SECTION 25 - FRONT AXLES 123

Remove discs (4) and (5).

4 5

F27456

Assembly

Apply a thin layer of Molicote G-n plus paste on half

housings of differential (3) and (12). 3 12

SWARNING
Remove rests of dope.

F27457

Apply a thin layer of Molicote G-n plus paste on

planetary gears (7), (11), and on planetary gears 8
(8).

11

F27458

Assemble discs (4) and (5).

4 5

F27456
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124 SECTION 25 - FRONT AXLES

Assemble planetary gears (11).

F27455

Assemble the differential unit pin (10) and planetary

gears (8) and washers (9).

9 9

8 8

10

F27454

Assemble planetary gears (7).

7

F27459

Assemble discs (4) and (5).

4 5

F27452
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SECTION 25 - FRONT AXLES 125

Assemble the two half housings of differential unit

(3) and (12).
12
SWARNING
Carefully check that the marks of both differential
half housings coincide.

F27451

Fit bevel gear crown (14) by using a hammer.

14

F29320

Apply Loctite 242 on thread of screws (1).

1
F27316

Tighten screws (1) to the requested torque.

NOTE: fix differential housing in the vice.

F27315
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126 SECTION 25 - FRONT AXLES

Press bearing (13) or assemble after preheating.

13

F27460

Press bearing (2).

F27318
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SECTION 25 - FRONT AXLES 127

PINION GROUP

1
2
3
4
5
6
7
8
9
10

F27461

Disassembly

Position the differential carrier in a vise.

Unscrew the locknut (10) using special tool
380002218.

NOTE: this operation will irretrievably damage the

locknut (10).
10

F27462
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128 SECTION 25 - FRONT AXLES

Remove the ring nut (10) and collect its retaining

washer (9).

9
10
F27463

Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8

SWARNING
Take care not to lower the bevel pinion (1).
5
Collect the washers (4) and (6), the collapsible 1
spacer (5) and the bearing cone (8).

6
4
F28106

Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and 3
a hammer.
7

8
F28107

To remove the bearing cone (3) of the bevel pinion

(1), use a standard extractor.
Collect the bearing cone (3) and the underlying shim
(2). 3

F27324
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SECTION 25 - FRONT AXLES 129

Check all pinion components for wear.

SWARNING
The ring nut (10) and the collapsible spacer (5) must 5
be replaced when reassembling the unit.
10

F27325

Assembly

Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8) using the special 3
drifts and a hammer.
7

8
F28107

Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.

F28108

Insert the bearing cones (3) and (8) in their hous-

ings.
Assemble the “false pinion” 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated.

3
8
10
F28109
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130 SECTION 25 - FRONT AXLES

Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.

F28110

Assembly diagram of the “false differential box”

tools on the bearing differential support seats.
Use a depth gauge to measure distance “X” (dis- X
tance between the axis of the differential bearings
and the point at which the pinion head is supported,
or base of the bearing). X

F28111

In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).

S = X-V mm
V

F27331

Select the shim (2) of thickness value (S) among the

range of available shims.

F27332
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SECTION 25 - FRONT AXLES 131

Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing cones (3) and (8).

3
8
10
F28109

Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool 380002224 under a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new collapsible
spacer (5).
1 1
NOTE: use always a new collapsible spacer (5).

F27334

Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing cone (8) into 8
the pinion shaft, as shown in figure.
In order to force the bearing (8) into position, use the
special tool 380002224 and a hammer.
It is advisable to offer resistance, for example a 5
sledge, to the beating force. 1

6
4
F28112

Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.

9
10
F27463
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132 SECTION 25 - FRONT AXLES

Screw the ring nut (10) in, using the wrench

380003218 for ring nut and for pinion retainer.

SWARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10

NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27445

to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.

Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.

P = 9.2÷13.7 daN

SWARNING
All preloadings must be measured without the seal
F27432
ring.

Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.

F27338
 Copyright ©

SECTION 25 - FRONT AXLES 133

TOE-IN / STEERING ANGLE

1 2 3 3 2 1

5 5

4 4

F28113

Toe-in

Put two equal one-metre-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.

SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
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134 SECTION 25 - FRONT AXLES

Measure the distance in mm M between the bars

ends with a tapeline.

NOTE: keep the minimum value, swinging the

measurement point.

F27341

Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5

M -05

F27342

If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1

F27343
 Copyright ©

SECTION 25 - FRONT AXLES 135

After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
1 2

F27344

Steering angle adjustment

Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.

F27345

Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.

F27346

Adjust the mechanical steering stop, screwing in or

out the stop bolt (4), locking it with the locknut (5) to
the requested tightening torque.

5 4

F27347
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136 SECTION 25 - FRONT AXLES

Steer completely towards the other side and repeat

the same operation.

F27348
 Copyright ©

SECTION 25 - FRONT AXLES 137

3.3 FAULT FINDING

PROBLEM CAUSE

1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise

1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with bigger
radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both tyres.

4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.

5. Bent half shaft

Replace half shaft.

6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all com-
ponents. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.

7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.

8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings etc.
Replace whenever necessary.

9. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.

10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.

11. Incorrect use of the product

See the vehicle producer’s instructions once again.

138
PROBLEM
Ring gear tooth broken on the
outer side
Ring gear tooth broken side
Pinion or ring gear teeth worn
Overheated ring and pinion teeth
See if gear teeth have faded
Pinion teeth pitting
Axle beam body bent
Worn out or pitted bearings
Oil leakage form gaskets and
seals
Excessive wearing out of input
flange spline
Fatigue failure of pinion teeth
See if the fracture line is well
defined
(wave lines, beach lines)
Pinion and ring teeth breakage
SECTION 25 - FRONT AXLES
CAUSE
Excessive gear load compared to
the one foreseen
Incorrect gear adjustment
(excessive backlash)
Pinion nut loose
Load bump
Incorrect gear adjustment
(insufficient backlash)
Pinion nut loose
Insufficient lubrication
Contaminated oil
Incorrect lubrication or depleted
additives
Worn out pinion bearings that
cause an incorrect pinion axle
backlash and wrong contact
between pinion and ring
Prolonged functioning at high
temperatures
Incorrect lubrication
Low oil level
Contaminated oil
Excessive use
Insufficient lubrication
Vehicle overloaded
Vehicle’s accident
Load bump
Insufficient lubrication
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Prolonged functioning at high
temperature of the oil
Oil gasket assembled incorrectly
Seal lip damaged
Contaminated oil
Exhaustive use
Pinion nut loose
Pinion axle backlash
Exhaustive use
Continuous overload
Crash load of differential
components
Copyright ©
ACTION
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Use correct lubricants, fill up to the
right levels and replace according to
the recommended program.
Replace bevel gear set.
Use proper lubrication, fill up to right
level and replace at recommended
program.
Replace bevel gear set.
Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Replace axle beam body.
Replace bearings.
Use correct lubrication, fill up to the
right level and replace at
recommended intervals.
Replace the gasket or seal and
matching surface if damaged.
Use correct lubrication and replace
at recommended intervals.
Replace the flange.
Check that the pinion spline is not
excessively worn out.
Replace bevel gear set if required.
Replace bevel gear set.
Check and/or replace other
differential components.

Side gear spline worn out
Replace all scratched washers
(Excessive backlash)
Thrust washer surface worn out
or scratched
Inner diameter of tapered roller
bearing worn out
Bent or broken half shaft
Half shaft broken at wheel side
SECTION 25 - FRONT AXLES
Excessive use
Insufficient lubrication
Incorrect lubrication
Contaminated oil
Excessive use
Excessive pinion axial backlash
Insufficient lubrication
Contaminated oil
Vehicle intensively operated or
overloaded
Wheel support loose
Beam body bent
Copyright ©
139
Replace differential gear group.
Replace half shaft if required.
Use correct lubrication and fill up to
right level.
Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Replace bearing.
Check pinion axial backlash.
Use proper lubrication, fill up to right
level and replace at recommended
intervals.
Replace.
Replace.
Check that wheel support is not
worn out or wrongly adjusted.
 Copyright ©

140 SECTION 25 - FRONT AXLES

4. SPECIAL TOOLS

P/N CNH USE 2WD 4WD 4WS

380000406 Disassembly/assembly of differential ring nuts / • •
380000407 + Calculation of pinion shims / • •
380000440
380002213 Assembly of seal ring in the wheel hub / / •
380002218 Disassembly/assembly of pinion rings / • •
380002219 Calculation of pinion shims / • •
380002222 Assembly of bearing cups in the wheel hub / / •
380002223 Disassembly and assembly bushings in the crown retainer hub / • /
380002224 Assembly of pinion bearing / • •
380002225 Assembly of front flange seal connection / / •
380002226 Assembly of bushing in the half beam / / •
380002227 Assembly of seal ring in the wheel hub • • /
380002432 Assembly of sliding block in the swivel housing / • /
380002660 Assembly of bushing in the swivel housing / • /
380002661 Assembly of seal ring in the swivel housing / • /
380002662 Assembly of spherical joint on lower and upper king pin / • /
380002663 Assembly of bearing cups in the wheel hub • • /
380002664 Assembly of bushing in the seat of the upper king pin / • /
380002665 Assembly of bushing in the half beam / • /
380002666 Assembly of seal ring in the half beam / • /
380002667 Disassembly/Assembly of bushings in the crown retainer hub / / •
380002668 Assembly of bushing in the swivel housing / / •
380002669 Assembly of seal ring in the swivel housing / / •
380002670 Assembly of seal ring in the half beam / / •
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 27 - REAR AXLE

1. REAR AXLE 2WS ......................................................................................................................................... 3

1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
 Copyright ©

2 SECTION 27 - REAR AXLE

 Copyright ©

SECTION 27 - REAR AXLE 3

1. REAR AXLE 2WS

1.1 DESCRIPTION AND OPERATION

The rear axle is a rigid axle and is fixed by 4 screws

to the chassis with a torque value of 800 Nm.
It incorporates the following features:
Z mechanically operated differential unit;
Z hydraulically operated oil immersed foot brakes fit-
ted with four disc brakes;
Z planetary reduction carrier with 3 planetary gears.
Power from the transmission output shaft is trans-
mitted to the rear axle through the flange (1), the 1 2 3
brake pads (2) and the half shaft (3) to the rear fire.
The bevel pinion is located in preloaded roller bear-
ings.
The differential is located on two roller bearings, the
right hand bearing supported by an internal web of
the axle centre housing.
The crown is fixed to the differential housing. Drive
from the housing is transmitted through a four pinion
differential to sun gear shafts which are splined into
the differential side gears. 6 5 4
The differential lock sliding coupling is located on the F29546

splines of the right hand differential side gear. The

coupling has dog teeth which engage with the dog
teeth on the differential housing lock adaptor.
If the dog teeth are not aligned, the spring engage-
ment link will be preloaded, ensuring rapid and full
tooth engagement when the dog teeth align.
The differential lock will remain engaged due to dog
tooth side loading as long as the rear wheels have
unequal traction.
The return spring disengages the lock when both
wheels have equal traction or drive is disengaged.
The brakes are mounted on the final reduction sun
gears. These brakes are wet disc type with hydraulic
piston actuator operated by foot pedals, independ-
ently for turning assistance, or together for transport.
The planetary gears (4) are mounted in a planetary
carrier and are positioned around the sun gear and
within the planetary ring gear (5). The rear axle
shafts (3) are located into the internal splines in the
carriers.
As the sun gear is driven by the differential, the re-
duction planet gears revolve inside the stationary
planetary ring gear and drive the carrier and axle
shaft at reduced speed.
The rear axle shaft is supported on taper roller bear-
ings (6). Preload is adjusted by means of selective
shims held under the retaining plate and screws.
 Copyright ©

4 SECTION 27 - REAR AXLE

ELECTRO-HYDRAULIC DIFFERENTIAL
LOCKING OPERATION (only Powershift)

SWARNING
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically op-
erated solenoid. The solenoid is energized when the
button (1) mounted in the right control lever.

The differential lock effectively places both rear

wheels into a direct drive when selected, this action
stops one rear wheel spinning.

In conditions inducing wheel slip (differential lock not

yet engaged), press down the differential lock switch 2 3
and the lock will engage giving direct drive to both
rear wheels.
The lock will remain engaged until either of the foot
brakes are applied and the machine stops or by dis-
engaging the switch. The warning light on the instru-
ment panel will go out when the differential lock has
disengaged.
When selecting switch (1) on gauge cluster, the dif-
ferential is activated with the oil pressure supplied by
the transmission, which acts on piston (3) for differ-
ential locking. 4 F29548

This oil under a pressure of 13-14 bar, always avail-

able when the engine is running, is controlled from
an electrovalve. When the switch is released (differ-
ential locking not necessary) oil is diverted to the fill-
er of the level dipstick (discharged) and the piston
spring (2) of the differential releases the locking (4).
 Copyright ©

SECTION 27 - REAR AXLE 5

MECHANICAL DIFFERENTIAL LOCKING

OPERATION (Powershuttle models)

SWARNING
Never use the differential lock at speeds above 8
km/h (5 mph) or when turning the machine. When
engaged the lock will prevent the machine turning
and personal injury could result.

In conditions inducing wheel slip, hold down the dif-

ferential lock pedal (1) with your heel until the lock is
felt to engage. The lock will automatically disengage
when traction at the rear wheels equalizes. If a rear
wheel spins at speed, reduce the engine speed to
idle before engaging the differential lock to minimize
shock loads on the rear axle.
When pedal (1) is pressed, a system of levers acti-
vates outer lever (2) that on its turn acts on bracket 2
(3) locking the differential. By releasing pedal (1) the
lever is also released and the differential is un-
locked. 3

F29549
 Copyright ©

6 SECTION 27 - REAR AXLE

1.2 TECHNICAL SPECIFICATIONS

F29550

POWERSHIFT POWERSHUTTLE RATIO

/ • 4.62:1
• / 4.11:1

LUBRICATION
Oil capacity: 21.2 litres
Oil specification: Akcela Hy-Tran Ultra MAT3525 + AoA Axle oil additive (0.8 litres)
 Copyright ©

SECTION 27 - REAR AXLE 7

TIGHTENING TORQUES

2 11 3 4

8 9 10

F29551

1. Screw of half shaft: 554÷626 Nm 7. Screw of baffle oil: 43÷51 Nm

2. Screw of axle assy - rear RH or LH: 190÷231 Nm 8. Plug: 27÷34 Nm
3. Screw of front flange: 136÷170 Nm 9. Screw: 32÷41 Nm
4. Screw to fixed rear axle to the chassis: 800 Nm 10. Screw of housing rear brake: 204÷245 Nm
5. Screw: 11÷14 Nm 11. Right nut: 406 Nm
6. Screw of block: 57÷76 Nm
 Copyright ©

8 SECTION 27 - REAR AXLE

1.3 DISASSEMBLY AND ASSEMBLY

REAR AXLE REMOVAL

For servicing of any rear axle component the axle
must be removed.
Prior to removal of the axle place a suitable clean
container under the axle, capable of holding 21.2 li-
tres and drain the oil from the plug at the base of the
axle.
Disconnect the differential lock lever.
Gain access from the top of the rear axle, disconnect
and drain the residual brake oil into a suitable clean
container. Remove the pipes from both sides of the
axle half shafts. Plug the brake pipes to prevent any
dirt or contamination entering the brake system.
Remove the 4 attaching screws from the drive shaft
coupling and remove from the axle.
Before removal of the axle make sure the machine is
on level ground with the loader fully lowered and
backhoe resting on the ground. The stabilizers must
be lowered to the ground and the front wheels
chocked.
Support the axle and remove the retaining screws,
gently lower the axle to the ground.
Place the axle on a suitable stand to facilitate the re-
pairs.
 Copyright ©

SECTION 27 - REAR AXLE 9

DIFFERENTIAL REMOVAL

Unscrew the upper screw (1). Use the hole of this

screw and holes (A) to install tool 380000990 for the 1
lifting of half-beam housing (2).
Unscrew and remove remaining screws (1).
A

2
F29552

Remove left housing of half-beam (2) with differen-

tial (3) using tool 380000990, from axle central body
(4).

At this point it is possible to remove from the left

housing of the half-beam the differential group assy.
The differential consists of:
Z differential lock spring (5);
Z differential housing (6);
Z crown wheel (7).
 Copyright ©

10 SECTION 27 - REAR AXLE

DIFFERENTIAL DISASSEMBLY

1. Lock ring 9. Bearing

2. Washer 10. Thrust washer
3. Dog gear 11. Side gear
4. Spring 12. Spider assembly
5. Dog 13. Side gear
6. Differential half housing 14. Thrust washer
7. Crown wheel 15. Differential half housing
8. Screw 16. Bearing screw

Prior to separating the differential, mark the two half

housings (6) and (15) to ensure correct reassembly.
Replace the differential lock coupling and adaptor if
worn or damaged.
 Copyright ©

SECTION 27 - REAR AXLE 11

The differential lock can be disassembled by com-

pressing the spring and carefully detaching the snap
ring (1).
With the snap ring removed disassemble the: wash-
er (2), outer dog (3), spring (4), inner dog (5) from
the housing (6).
Carefully inspect all moving parts for signs of scor-
ing, wear, or damage, if evident replace with new
parts.

By means of an extractor remove the bearing (16).

Unscrew and remove the screws (17). Disassemble

the half-housing of differential (15).

Now remove the thrust washer (10) and (14), the

planetary gears (11) and (13) and the spider gears
(12).
 Copyright ©

12 SECTION 27 - REAR AXLE

PINION REMOVAL

1. Ring nut 9. Disc

2. Lock pin 10. Seal
3. Washer 11. Bearing
4. Seal 12. Pinion
5. Coupling 13. Bearing
6. Bearing 14. Lock ring
7. Spacer 15. Screw
8. Flange

Remove the lock pin (2) to unlock the ring nut (1).
 Copyright ©

SECTION 27 - REAR AXLE 13

Using the special tool 380002675 hold the coupling

(5) steady while loosening the ring nut (1).

Remove the ring nut (1), the washer (3) and the gas-
ket (4).
Remove the coupling (5).

Unscrew and remove the screws (15).

Remove flange (8).

Remove the bearing (6) from the flange (8).

 Copyright ©

14 SECTION 27 - REAR AXLE

Remove the snap ring (14) from the axle inner cen-
tral body.
Using an rubber hammer, take out the pinion (12). 12

14

F29553

Remove from the pinion (12), the spacer (7) and by

means of extractors, the bearings (11) and (13).
 Copyright ©

SECTION 27 - REAR AXLE 15

BRAKE GROUP DISASSEMBLY

Powershuttle

14
17
11
10
9 16
8 2
7 3
6 4
5 5
4 6
3 15 RH
2 13
1 12

LH
F29554

Powershift

18
19 1
20 2
15 3
6 4
5 6
4 5
3 7 RH
2 12
16 13

LH
F29555

1. Housing brake outer 11. Block (Powershuttle)

2. O-ring 12. Washer
3. O-ring 13. Screw
4. Piston brake 14. Screw
5. Disc brake intermediate 15. Housing brake inner
6. Disc brake 16. Housing brake outer
7. Housing brake inner 17. Screw
8. Baffle oil (Powershuttle) 18. Baffle oil (Powershift)
9. Screw 19. Block (Powershift)
10. Shim 20. Screw
 Copyright ©

16 SECTION 27 - REAR AXLE

Unscrew and remove the screws (17) then disas-

semble the block (11) with the shims (10). 10 11

17

12 13
8
F29556

Untighten and remove the screws (9). Remove the

housing brake inner (7).

Remove the brake pads (6) and the intermediate

brake pads (5). 6 5

F29557

Remove the brake piston (4) and the outer housing

brake (1).
 Copyright ©

SECTION 27 - REAR AXLE 17

AXLE SHAFT ASSY RH/LH DISASSEMBLY

1. Sun gear 9. Screw

2. Retainer 10. Screw bleeder
3. Screw 11. O-ring
4. Washer 12. Axle housing assy right or left
5. Shim 13. Bearing
6. Planetary gear carrier 14. Seal
7. Bearing 15. Shaft with wheel hub
8. Manifold brake tube 16. Epicyclic ring gear

The brake manifold (8) can be removed by loosen-

ing and removal of the screws (9). Before reassem-
bly fit a new O-ring (11). On reassembly torque the
attaching screws to 11 - 14 Nm.
 Copyright ©

18 SECTION 27 - REAR AXLE

Remove the sun gear (1).

To remove the planetary gear carrier assy (6) from

the carrier (16), remove the lock shaft (2), the retain-
ing screw (3), the washer (4) and the shim (5).

Remove the planetary gear carrier assy (6).

If necessary it is possible to disassemble the plane-

tary gear carrier assy:
Z Remove the retaining ring (A).
Z Extract gears pins (B) and remove planetary gears
(C).
 Copyright ©

SECTION 27 - REAR AXLE 19

The planetary ring gear (16) can be removed from

the axle (12) with the aid of tool 380000816. Position
the tool beneath the ring gear, expand the plates
and tighten the screws. Invert the axle and press out
the gear from the wheel hub side.
Inspect the gear for wear, scoring or damage and
repair or replace.

Position the axle housing (12) to allow removal of

the shaft with wheel hub (15).

Using the puller tool 380000986 and the slide ham-

mer 380000987, remove the bearing cups (13) from
the axle housing (12).

By means of extractor 380002676 remove the bear-

ing (13) from the axle shaft (15).
Applying gradual pressure to the tool, the bearing
will separate from the half axle.
Inspect the bearing for wear, scoring or damage and
replace if in any doubt.
 Copyright ©

20 SECTION 27 - REAR AXLE

Reassembly of the bearing is the reverse proce-

dure. Using an induction heater, heat the bearing
sufficiently to expand it enough to allow it to easily
seat onto the half shaft.

After bearing removal, disassemble the seal (14)

from the shaft with wheel hub (15).

NOTE: always fit a new axle seal if the axle bearing

is removed for any reason.
 Copyright ©

SECTION 27 - REAR AXLE 21

MEASUREMENTS AND ADJUSTMENTS

BEARING OF BEVEL PINION PRELOAD

The pinion bearing preload is set by selecting the

correct shim (spacer) which is placed between the
bearings.
Reassemble the pinion assembly, attach the fabri-
cated spanner 380002675 to the flange (1) and
torque to 406 Nm with spanner to the locknut (2).

MEASURING OF PINION ROLLING TORQUE

Use a torque metre (1) to check rolling resistance

when the assembly is fitted back into the axle.
The rolling resistance should be: 1.3 Nm. Leave pin-
ion retainer screws loose for this check.
If under specification, fit a smaller shim. If over spec-
ification, fit a larger shim.

AXLE SHAFT BEARING PRELOAD

The preload of the axle shaft bearing is realized by X

placing the shims (1) between axle shaft (2) and 1 2
washer (3) as many as necessary to achieve value
X.

3
F29558
 Copyright ©

22 SECTION 27 - REAR AXLE

The procedure to determine value X occurs in the

following manner:
Z install the largest shim (for instance 2.286 mm);
Z assemble the planetary gear assy;
Z screw and tighten screw at 554÷626 Nm;
Z by means of a dial gauge find out the axle backlash
(for instance 0.562 mm);
Z subtract endfloat from shim already fitted, for
example 2.286 - 0.562 mm = 1.724 mm.
The “Resultant value” is obtained.
Z starting from “Resultant value” refere to table for
correct shim to replace the 2.286 one.

IMPORTANT: increasing shim thickness will reduce

preload. Decreasing shim thickness will increase
preload.

Z fit selected shim and re-tighten retained screw to

correct torque and allow lock plate to locate.

RESULTANT VALUE SHIM TO BE INSTALLED

1.245 - 1.270 mm 81803491
1.346 - 1.372 mm 81803502
1.448 - 1.473 mm 81803503
1.549 - 1.575 mm 81803504
1.651 - 1.676 mm 81803505
1.753 - 1.778 mm 81803506
1.854 - 1.880 mm 81803507
1.956 - 1.981 mm 81803508
2.057 - 2.083 mm 81803509
2.159 - 2.184 mm 81803510
2.261 - 2.286 mm 81803511
 Copyright ©

SECTION 27 - REAR AXLE 23

MEASURING OF AXLE SHAFT ROLLING TORQUE

After fitting the correct shim to set the preload: man-

ufacture a bridging bar to span opposing screw
holes to the dimensions shown.

Fit bridging bar (1) across the rear axle housing

flange and use a torque metre (2) to check rolling re-
sistance which should be 2.3 - 10 Nm.

NOTE: the brake housing, brake pads and sun gear

should not be installed but all bearings well lubricat-
ed.

If out of specification the shim should be adjusted

and rolling resistance rechecked.
 Copyright ©

24 SECTION 27 - REAR AXLE

DIFFERENTIAL BEARING PRELOAD

This adjustment is made by shimming the right hand

differential bearing cone.
The value of following shimming is required: dimen-
sion “T”.

VALUE “T”
SHIMS
mm
0.034 ÷ 0.039 81803515
0.040 ÷ 0.045 81803516
T
0.046 ÷ 0.051 81803517 F29559

0.052 ÷ 0.057 81803518

0.058 ÷ 0.063 81803519
0.064 ÷ 0.069 81803520
0.070 ÷ 0.075 81803521
0.076 ÷ 0.081 81803522

Remove the differential bearing cone and shim from

the outer brake housing.
Place the gauge ring of tool 380000991 (1) into the
vacant bearing location.
Screw bridge tool 380000991 (1) across the rear
axle housing flange with spacers (2) located be-
tween the axle housing flange and the tool.
Measure the gap between the bridge tool and the
gauge ring using a feeler gauge (3).
Refer to the table to determine the correct size shim
which should be installed between the brake hous-
ing and bearing cone, thus preloading the bearing
back to specifications.
 Copyright ©

SECTION 27 - REAR AXLE 25

MEASURING OF RANGE BETWEEN THE FACE THRUST BLOCK AND THE BACK FACE OF
DIFFERENTIAL

For dimensions “S” outside normal gap range use

as required the minimum number of shims to pro-
vide design gap of 0.10 - 0.20 mm. S

VALUE “S”
SHIMS
mm
0.80 ÷ 0.89 87346232 + 87346228
0.90 ÷ 0.99 87346232 + 87346231
1.00 ÷ 1.10 87346232 + 87346427 F29560

This procedure has the goal to get a clearance of

0.10 mm to 0.20 mm between the thrust face of the
thrust block and the back face of the differential bev-
el gear.
To get this setting we perform two measurements to
calculate the shim pack to be used.

Z On the centre housing, with the differential assy in-

stalled and centered, we check the distance from
the back of the bevel gear to the trumpet mounting
face of the centre housing. During this measure-
ment rotation of the differential is needed to get the Y
shortest reading. This is to take the run-out of the
back face in calculation thus to avoid interference
afterwards (dimension Y).
Y: dimension from back of differential bevel gear to
trumpet mounting face.

F29637

A: gauge clamped on housing and differential

aligned to check the dimension “Y”.

F29638
 Copyright ©

26 SECTION 27 - REAR AXLE

Z Assemble the thrust block to the trumpet housing

(NO SHIMS mounted in between the parts!).
Check the distance from the thrust face of the X
thrust block (1) to the centre housing mounting
face of the trumpet housing (2) (dimension X).
1 2

F29639

B: gauge on trumpet housing.

F29640

S= Y-X will give you the minimum gap between the

thrust block and the back of the differential bevel
gear. Based on this calculation and the attached
shimming chart people find the shims to be used.
Shim pack thickness to be checked prior installation.
Disassemble the thrust block, fit the shim pack in
between the thrust block and the trumpet housing
and reassemble thrust block again.

Check free rotation of axle input on the completed

axle sub-group.

1.4 FAULT FINDING
PROBLEM
Differential lock not engaging
(mechanical differential lock)
Differential lock not disengaged
(mechanical differential lock)
Differential lock not engaging
(electrical differential lock)
Differential lock not disengaged
(electrical differential lock)
SECTION 27 - REAR AXLE
CAUSE
External linkage damaged or broken Replace/repair as required.
Internal linkage, cross shaft rod,
fork or pivot shaft damaged/
broken
Damaged or broken teeth on
differential lock adaptor or
coupling
Spring broken between adaptor
and coupling
Teeth of adaptor or coupling
damaged/burred
Internal linkage, cross shaft rod,
fork or pivot shaft damaged/
broken
Damaged or broken teeth on
differential lock adaptor or
coupling
Solenoid valve sticking not
operating
Solenoid valve electrical
connection poor or coil not
energizing
Spring broken between adaptor
and coupling
Teeth of adaptor or coupling
damaged/burred
Internal linkage, cross shaft rod,
fork or pivot shaft damaged/
broken
Damaged or broken teeth on
differential lock adaptor or
coupling
Solenoid valve electrical
connection poor or coil not
energizing
Copyright ©
27
ACTION
Remove and inspect.
Remove differential and inspect
differential lock assembly.
Remove differential and replace
spring.
Remove differential and replace
damaged parts.
Remove, inspect and repair.
Remove differential and inspect
differential lock assembly.
Replace/repair as required.
Replace/repair as required.
Remove differential and replace
spring.
Remove differential and replace
damaged parts.
Remove and inspect.
Remove differential and inspect
differential lock assembly.
Replace/repair as required.
 Copyright ©

28 SECTION 27 - REAR AXLE

2. REAR AXLE 4WS “CARRARO”

2.1 TECHNICAL SPECIFICATIONS

Rear steering axle, model 26.32M

F28003

POWERSHIFT SELF LOCKING RATIO

• / 19.038
• • 19.038
 Copyright ©

SECTION 27 - REAR AXLE 29

LUBRICATION AND GREASING

Differential oil capacity 11 litres

Epicyclic reduction gear oil capacity each side 1.3 litres
Oil specification:
use recommended oil enriched in additives
Akcela Nexplore MAT3525
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
Grease specification Akcela Multi-
purpose grease
251H-EP

3 5 7 1 6 6 1 7 2

4
F28004

DESCRIPTION POSITION
Differential oil filling and level plug 1
Oil breather 2
Fill / drain and level plug of epicyclic reduction gear oil 3
Differential oil drain plug 4
Greasing points 5
Brake bleed plug 6
Service brake oil port 7
 Copyright ©

30 SECTION 27 - REAR AXLE

Before draining the oil, loosen the oil breather (2) to

release possible internal pressure, then tighten the 2
plug to the requested torque.

F28005

To drain the oil from the central body unscrew the

plug of the draining hole (4) and level hole (1).
Then tighten them to the specified torque.

4 1

F28006

Before draining the oil, position the wheel hub so

that the filler cap is in the highest point, then loosen
the plug (3) to release possible internal pressure.

F28007

Position the wheel hub so that the filler cap is on the

centre line of the horizontal axis.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the pre-
scribed torque.

F28008
 Copyright ©

SECTION 27 - REAR AXLE 31

Before draining the oil, loosen the breather (6) to re-

lease possible internal pressure.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the pre-
scribed torque.

6
F28009
 Copyright ©

32 SECTION 27 - REAR AXLE

2.2 DISASSEMBLY AND ASSEMBLY

FRONT FLANGE

7
6
5
4

1 2 3

F28010

Disassembly

Remove the snap ring (1).

F28011
 Copyright ©

SECTION 27 - REAR AXLE 33

Remove the front flange (2).

F28012

Remove the seal (3), the O-ring (4), the gasket (5),
the O-ring (6) and the washer.
5
4
3

7
6
F29009

Assembly

Assemble the washer (7) and the new O-ring (6).

7
6
F29322

Assemble the gasket (5).

F29323
 Copyright ©

34 SECTION 27 - REAR AXLE

Assemble the new O-ring (4) and the seal (3).

4
3

F29324

Assemble the front flange (2).

F28012

Assemble the snap ring (1).

F28011
 Copyright ©

SECTION 27 - REAR AXLE 35

STEERING CYLINDER

4
5
7
3 10
11
12
2

6
8 13
9
14

15
16
17
18
19
20
21
22
23
24

F28013

Disassembly

Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).

SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3

NOTE: this is a destructive operation for the nut (1). 1

2
F27228

Repeat the whole sequence at the other side.

 Copyright ©

36 SECTION 27 - REAR AXLE

Remove the tie rods (3) and (13) by loosing the nuts
(4) and (12) with a suitable wrench, then check the 4
conditions. 5
Unscrew the fastening screws (6) and (9) and take
7
10
the steering cylinder (7) out of its housing, if neces- 11
12
sary use a rubber hammer.
Remove only parts that need to be overhauled and/
or replaced.

3 6 8 9 13
F28014

Remove the cylinder head (22) from the cylinder

body (18) and remove it from the rod (20). 16
Remove the rod (20) from the cylinder body (18). 18
Remove all the seals and O-rings (16, 17, 19, 21, 23 20
and 24) from the cylinder body (18), the cylinder 21
head (22), and the rod (20).
17
19
22
23
24
F28015

Assembly

Assemble new seals and O-rings (16, 17, 19, 21, 23

and 24) on the cylinder head (22), on the rod piston 16
18
(20) and on the cylinder body (18).
20
21

17
19

22
23
24
F28016

Assemble the tie rods (3) and (13), the ball joints (5)
and (11), the nuts (4) and (12) to the ends of the rod, 4
then tighten with a dynamometric wrench to the re- 5
quested torque. 7
10
11
12

13
F28017
 Copyright ©

SECTION 27 - REAR AXLE 37

Install the steering cylinder (7) already assembled

on the central body.
Assemble and tighten the screws (6) and (9) to the
requested torque.

Align the swivel housing (14) with the axle.

Screw the tie rod (13) so that its ball joint can be in- 12 13
serted into the swivel housing (14) arm.

NOTE: it is important to unscrew the locknut (12) to

carry out this operation.

Repeat the whole sequence of the mentioned oper-

ations to the other side.

14
F28020

Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
Repeat the whole sequence of the mentioned oper-
ations to the other side.
1

F27236
 Copyright ©

38 SECTION 27 - REAR AXLE

EPICYCLIC REDUCTION GEAR

11
9
10
8
7
6
5

1
3
2

F27404

Disassembly

Drain the oil completely from the planetary carrier.

F27240
 Copyright ©

SECTION 27 - REAR AXLE 39

Unscrew and remove both fastening screws (3) of

the planetary carrier (1).
3

F28044

Remove the planetary carrier (1) from the wheel

hub.
Position the planetary carrier (1) on a workbench
and check its wear conditions.

F27405

To replace the epicyclic gears, if necessary, remove

the screw (11) and relevant washers (8) and (9). 10 11

NOTE: treat the pin (10) with care. 9

F28021

Remove the epicyclic gear (7) from its seat, taking

care not to lose the rollers inside it. 7
Remove the shim (5).
5

F28022
 Copyright ©

40 SECTION 27 - REAR AXLE

If the pins of the pinion gears are in poor condition,

replace the entire planetary train with pre-fitted pins.

F28023

Assembly

Place the planetary carrier on a work bench and fit

the epicyclic gears (7) and respective shims (5).
7

F28024

Insert all the rollers into the epicyclic gears, then

place the two thrust washers (8) and (9).
9
NOTE: the first washer must be aligned with the
dowel (10) pin. 10 8

F28025

Screw and tighten the screws (11) to the requested

torque.
11

F28026
 Copyright ©

SECTION 27 - REAR AXLE 41

Assemble the planetary carrier (1) on the wheel hub.

F27405

Screw in screws (3) and tighten to the requested

torque.
3

F28044

To up the oil on the wheel hub.

Assemble the filling/drain and level oil plug (2) on 2
the planetary carrier (1) and tighten to the requested
torque.

F27408
 Copyright ©

42 SECTION 27 - REAR AXLE

WHEEL HUB

Disassembly

Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to allow the lock ring removal.

SWARNING
Do not damage the double U-Joint.

14
F27410
 Copyright ©

SECTION 27 - REAR AXLE 43

Remove the lock ring (1) from the double U-Joint

shaft. 3 2
Collect the double U-Joint shaft washers (2) and (3).

F27250

Unscrew and remove the fastening screws (5) from

the wheel carrier (7).
7

F27251

To extract the wheel carrier screw two of the just re-

moved screws (5) in the threaded holes. 5
Remove the wheel carrier (7) with the epicyclic ring
gear (4). 7

F27253

Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- 6
cial tool 380002667.
7

F27252
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44 SECTION 27 - REAR AXLE

Remove the O-ring (15).

Remove the wheel hub (11) using levers and a ham- 15
mer to facilitate the operation.
11
NOTE: collect the bearing cone (9).
9

F27254

Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a lever. 13
12
NOTE: destructive operation for the seal ring (13). 11
Remove the bearing cups (9) and (12) using a ham- 10
mer and a suitable drift. 9
Remove the bearing cone (12) from the swivel hous-
ing end using a suitable extractor.

F27412

Unscrew and remove the fastening screws (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
rent safety regulations to guarantee operator’s safe- 14
ty.

Remove the king pins (16) and (18).

F27256

Remove the swivel housing (14) from the axle beam

and from the short shaft of the double U-Joint.

14

F27257
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SECTION 27 - REAR AXLE 45

Collect the thrust washers (23) and (28).

28

23

F28046

Position the swivel housing (14) on a flat surface

and take the seal ring (22) out with a lever.

NOTE: this is a destructive operation for the seal

ring. 22

Turn the swivel housing and take the bush (26) out,
using a suitable drift and a hammer.

14 23
F27259

Assembly

If it has been previously removed, reassemble the

steering stop composed by the screw (21) and nut
(20).

NOTE: do not tighten the nut (20) until the steering

angle adjustment has been done.

20 21

F27260

Force the bush (26) into the swivel housing (14) with
the special tool 380002668 and a hammer.
Assemble the seal ring (22) on the swivel housing
(14) with the special tool 380002669 and a hammer. 14
Grease carefully the seal ring (22). 26
22

F28047
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46 SECTION 27 - REAR AXLE

Grease well the king pin housings with specific

grease.
Position the thrust washers (23) and (29). 28

23

F28046

If ball joints (24) and (27) have been previously re-

moved, reassemble them on the king pins (16) and 24 27
(18).
18 16

F28027

Secure the swivel housing (14) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 14
ring.

F27257

Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19

16 18

F27263
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SECTION 27 - REAR AXLE 47

Position the wheel hub (11) on a workbench and as-

semble the bearing races (9) and (12) in position 9 12 13
with the special tool 380002222 under a press or
with a hammer.
Assemble the seal ring (13) into the wheel hub (11)
with the special tool 380002213 and a hammer.

11 11
F28028

Assemble the bearing cone (12) on the swivel hous-

ing (14). 14
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing cone (9). 12 9

F27265

Position the wheel carrier (7) on a workbench and

force the bushes (6) to the carrier surface level with 6 7
the special tool 380002667.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.

F27266

Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8). 8
7
4

F27267
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48 SECTION 27 - REAR AXLE

Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.

F27268

Force all the hub dowel bushes (6) completely with

the special tool 380002667 and a hammer. 6 5
Apply sealant on fastening screws (5) thread.
Assemble the wheel carrier (7) fastening screws (5) 7
and tighten to the requested torque.

F27269

Assemble the thrust washers (2) and (3) onto the

double U-Joint shaft end. 3 2
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.

NOTE: check that the lock ring (1) is correctly fitted

1
in its seat.

F27250
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SECTION 27 - REAR AXLE 49

DOUBLE U-JOINTS

4
3
2
1

F27279

Disassembly

Remove the two double U-Joints (1) from the axle

beam (4).

4
1

F27280
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50 SECTION 27 - REAR AXLE

Remove the seal rings (2) from the axle beam (4).

NOTE: destructive operation for the seal rings (3).

3
Remove the bush (3) from the axle beam (4) only if 2
the wear conditions require this.

SWARNING
Be careful not to damage the bush seat.

2
F27281

Assembly

Assemble the bush (3) on the axle beam with the

special tool 380002226 and a hammer. 2 3
Assemble the seal ring (2) on the axle beam with the
special tool 380002670 and a hammer.

F28029

Assemble the seal ring (2) as in figure.

F28048

Insert the double U-Joint (1) inside the axle beam

(4).

SWARNING
Be careful not to damage the seal ring.

4
1

F28049
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SECTION 27 - REAR AXLE 51

AXLE BODY AND BRAKES

Disassembly

Put alignment marks on the axle beam body and on

the differential supporting flanges, in order to identi-
fy the right side and the left side with certainty.

F28031
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52 SECTION 27 - REAR AXLE

Position the axle on supports fitted to hold either the

central body or the axle-beam, even after their dis-
junction, or secure the three disjointed groups to a
lifting device with ropes or belts.
Unscrew the screws (2) to disassemble the axle
beam trumpet (1).

2 1
F28033

Remove the axle beam trumpet (1).

SWARNING 4
Once the axle beam trumpet has been removed, the
brake disks are free. 1

Remove the O-ring (4).

F28034

Remove the brake counter disks (9) and the brake

pads (10). 15
Remove the grooved sleeve (8), the remaining
10
brake disk and the brake counter disk (15).
9
8

F28035

Secure the brake flange (7) to a hoist with ropes or

safety belts.
Unscrew the upper fastening screw (5) and the low-
er stud bolt (6). Remove the flange (7) from the cen-
tral body, together with the bevel gear backlash-
adjusting ring nut.
5 6
SDANGER
This operation frees the differential box, that acci-
dentally could fall.
7
F28036
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SECTION 27 - REAR AXLE 53

Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions. 4

19
F28037

Collect the brake flange (7) and place it on a work-

bench or fix it in a clamp.
Unscrew the self-adjust screws (11).
11

F27313

Take from the piston (14), the springs (13) and the
bushes (12) and (27) and spacer (26). 27
26

14
13
12
F28038

Unscrew the breather (21) from the brake flange (7).

21 7

F28039
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54 SECTION 27 - REAR AXLE

Take the piston out (14).

If necessary, blow in air through the brake bleeder 16 17 14
vent to eject the piston, using the minimum pres-
sure.
Remove the O-rings (16) and (17) from the piston
(14) and check their conditions.

F28040

Assembly

Assemble the O-rings (16) and (17) on the piston

(14) and lubricate the fraying surface piston/flange 16 17 14
with a light layer of grease.

F28040

Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
14
anchored to an eyescrew, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
7

F28042

Collect the self-adjust kits components and insert

them in the piston (14).
14
Insert the tightening screws (11) and tight to the re-
quested torque.
11

F28116
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SECTION 27 - REAR AXLE 55

Assemble the new O-rings (4) e (19).

4

19
F28037

Assemble and tighten the upper fastening screw (5)

and the lower fastening stud screw (6) of the brake
flange (7) to the requested torque.

5 6

F28043

Assemble the brake counter discs (9), and discs

(10), the spline hub (8) and the brake counter disc 15
(15).
10
9
8

F28035

Assemble the new O-ring (4).

In order to place the axle beam correctly, position
the half-beam (1) check the reference marks carried 4
out during disassembly.
1
NOTE: if new brake pads are installed, before as-
sembling, they should be dipped in the required oil.

F28034
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56 SECTION 27 - REAR AXLE

Assemble the axle-beam (1) on the flange, being

careful to the fastening holes’ alignment.

SWARNING
Support the groups properly as already pointed out
for disassembly phase.

Screw in and tighten the fastening screws (2) of the

axle beam trumpet to the requested torque.

2 1
F28033
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SECTION 27 - REAR AXLE 57

DIFFERENTIAL GROUP (STANDARD)

4
5

15
10
14
6
18
9
3 17
2 16
1
5 13
4 14
15

12
11
8
7
6 F28050

Disassembly

Unscrew the fastening screw (4) and remove the

ring nut retainer (5). 4 5
Unscrew the ring nut with suitable special tool
320002218.
Remove the ring nut (6).

6
F28051
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58 SECTION 27 - REAR AXLE

Remove the bearing cups (6).

6

F28052

Support the differential box assy (2) with a rod and

remove it. 2

F28053

Use an extractor to remove bearing (18) from differ-

ential unit.

18

F28054

Use an extractor to remove bearing (7) from differ-

ential unit.

F28055
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SECTION 27 - REAR AXLE 59

Unscrew all fastening screws (1) of bevel gear

crown (10). 10

SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.

F28056

Remove the bevel gear crown (10) by means of a

mallet.

10

F28057

Check marking points (8) and (9) that will be useful

during the assemblage.
9

F28058

Remove planetary gear (16) and shim (17).

17

16

F28059
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60 SECTION 27 - REAR AXLE

Remove differential pins (13), planetary gears (14)

and spheric washers (15).

15 15

14 14

13

F28060

Remove planetary gear (12) and shim (11).

12

11

F28061

Assembly

Apply a thin layer of Molicote G-n plus paste on half

housing of differential (8) and (9). 8 9

SWARNING
Remove rests of dope.

F28079

Apply a thin layer of Molicote G-n plus paste on

planetary gears (12), (16) and on planetary gears 14
(14).

12

16

14

F28063
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SECTION 27 - REAR AXLE 61

Assemble planetary gear (16) with shim (17).

16

17

F28064

Assemble the differential unit pin (13) and planetary

gears (14) and washers (15).

15 15

14 14

13

F28060

Assemble planetary gear (12) with shim (11).

11

12

F28066

Assemble the two half housings of differential unit

(8) and (9).
9
SWARNING
Carefully check that the marks of both differential
half housings coincide.

F28058
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62 SECTION 27 - REAR AXLE

Assemble the bevel gear crown (10) by using a

hammer.
10

F28067

Apply Loctite 242 on thread of screws (1).

1
F27316

Tighten screws (1) to the requested torque.

NOTE: fix differential housing in the vice.

F27315

Press bearing (18) or assemble after preheating.

18

F28068
 Copyright ©

SECTION 27 - REAR AXLE 63

Press bearing (7).

F28069

Support the differential box assy (2) with a rod and

assemble it. 2

F28070

Fit the outer cups of taper roller bearings (7) by

means of special tool 380002671 and a hammer.

F28071

Insert and tighten the adjusting ring nuts (6), using

the wrench 380002218 until the clearance of bear- 6
ings is removed.

NOTE: tighten the ring nuts gradually but not exces-

sively.

Assemble the ring nut retainer (5) and fasten it by

means of screw (4).
4 5
F28072
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64 SECTION 27 - REAR AXLE

DIFFERENTIAL GROUP (SELF-LOCKING)

4
5
6

16 15

17 10
17
18
16
9
15 11
3 12
2
13
1
5 19
4 16
15
16
15

14
13
12
6 7 8 11
F28073

Disassembly

Unscrew the fastening screw (4) and remove the

ring nut retainer (5). 4 5
Unscrew the ring nut with suitable special tool
380002218.
Remove the ring nut (6).

6
F28051
 Copyright ©

SECTION 27 - REAR AXLE 65

Remove the bearing cups (6) with a hammer.

6

F28052

Support the differential box assy (2) with a rod and

remove it. 2

F28053

Use an extractor to remove bearing (18) from differ-

ential unit.

18

F28054

Use an extractor to remove bearing (7) from differ-

ential unit.

F28055
 Copyright ©

66 SECTION 27 - REAR AXLE

Unscrew all fastening screws (1) of bevel gear

crown (10). 10

SWARNING 1
This operation makes both differential half housings
free, so take care not to lower the inner compo-
nents.

F28056

Remove the bevel gear crown (10) by means of a

mallet.

10

F28057

Check marking points (8) and (9) that will be useful

during the assemblage.
9

F28058

Remove discs (11) and (12).

11 12

F28074
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SECTION 27 - REAR AXLE 67

Remove planetary gear (19) and shim (13).

19

13

F28075

Remove differential pin (17), planetary gears (16)

and spheric washers (15).

15 15

16 16

17

F28076

Remove planetary gear (14) and shim (13).

14
13

F28077

Remove discs (11) and (12).

11 12

F28078
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68 SECTION 27 - REAR AXLE

Assembly

Apply a thin layer of Molicote G-n plus paste on half

housings of differential (8) and (9). 8 9

SWARNING
Remove rests of dope.

F28079

Apply a thin layer of Molicote G-n plus paste on

planetary gears (14), (19) and on planetary gears 16
(16).

14

19

16

F28080

Assembly discs (11) and (12).

11 12

F28078

Assembly planetary gear (14) with shim (13).

14
13

F28077
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SECTION 27 - REAR AXLE 69

Assemble the differential unit pin (17) and planetary

gears (16) and washers (15).

15 15

16 16

17

F28082

Assemble planetary gear (19) with shim (13).

19

13

F28081

Assemble discs (11) and (12).

11 12

F28074

Assemble the two half housings of differential unit

(8) and (9).
9
SWARNING
Carefully check that the marks of both differential
half housings coincide.

F28058
 Copyright ©

70 SECTION 27 - REAR AXLE

Assemble the bevel gear crown (10) by using a

hammer.
10

F28067

Apply Loctite 242 on thread of screws (1).

1
F27316

Tighten screws (1) to the requested torque.

NOTE: fix differential housing in the vice.

F27315

Press bearing (18) or assemble after preheating.

18

F28068
 Copyright ©

SECTION 27 - REAR AXLE 71

Press bearing (7).

F28069

By means of a rod insert the differential box assy

(2). 2

F28070

Fit the outer cups of taper roller bearings (7) by

means of special tool 380002671 and a hammer.

F28071

Insert and tighten the adjusting ring nuts (6), using

the wrench 380002218 until the clearance of bear- 6
ings is removed.

NOTE: tighten the ring nuts gradually but not exces-

sively.

Assemble the ring nut retainer (5) and fasten it by

means of screw (4).
4 5
F28072
 Copyright ©

72 SECTION 27 - REAR AXLE

BEVEL PINION GROUP

1
2
3
4
5
6
7
8
9

F28083

Disassembly

In order to avoid serious damages to the bevel pin-

ion thread, unscrew the ring nut (9) with the special
tool 380000406.
9

F29645
 Copyright ©

SECTION 27 - REAR AXLE 73

Once the ring nut washer has been removed, take

the pinion (1) out of its housing, by beating with a
hammer made of soft material on the splined end.
1

F28085

Remove the washer (6), the ring (5) and the shims
(4) from the bevel pinion (1).

1
4
5
6
F28086

Remove the bearing (3) from the bevel pinion (1),

using an extractor. 1
Remove the adjusting shim (2) placed under the
bearing and check its wear conditions.

3 2

F28087

Remove the bearing cup (7) from the central body.

F28088
 Copyright ©

74 SECTION 27 - REAR AXLE

Remove the outer bearing cup (3) from the central

body.
3

F28089

Assembly

Position the central body on a workbench.

Force the cups of the bearings on their housings us-
ing the special tool 380002215 for outer bearing
race and for inner bearing race.

F28090

In order to measure the distance, the kit composed

of the special tools, respectively called “false pinion”
380002673 and “false differential box” 380002674,
is used.
Insert the false pinion, together with its bearings and
its ring nut, in the just mounted housings for the
bearings.
Tighten without exceeding, till the backlash is elimi-
nated.

F28091

Check the correct positioning of the right and left

flanges, using the reference marks on them and on
the central body.
Assemble the two brake flanges and fix them with
their screws (screw in at least two ones diametrical-
ly-opposed for each flange).

F28092
 Copyright ©

SECTION 27 - REAR AXLE 75

Insert the false differential box 380002674 into the

central body to measure the distance.
Check that the false box is inserted in both brake
flanges’ housings.

F28093

Carry out the measurement with a depth gauge

through the suitable false pinion hole.
X= (conical distance to be measured)
A= (measured value)
B= (known value)= 100 mm

C
X
C= (known value)= 50 mm
(A+C) - B = X

A
B
F28094

In order to determine the shim (S) necessary be-

tween the pinion and the bearing, you should sub-
tract the (V) value stamped on the pinion head (V =
requested conical distance) from the (X) value.
S = X-V
V

F27331

Remove the false pinion, the bearings and the ring

nut from the central body.
Disassemble the false differential box from the
flanges and then unscrew the screws to remove the
flanges.

F28095
 Copyright ©

76 SECTION 27 - REAR AXLE

Insert the shim (2) on the bevel pinion (1) with cham-
fer against the gear.
Press the bearing (3) into the pinion, making sure 3
that it is well set.

1
F28096

Insert the shims (4) and (6) and the ring (5) into the
bevel pinion (1).

1
4
5
6
F28086

Insert the bevel pinion (1) unit into the central body
housing and the bearing (7) cone into the pinion
end. 1

F28097

Insert a new washer (8) and a new ring nut retainer

(9).
Screw the ring nut in, using the wrench 380000406
for ring nut and for pinion retainer.
8 9
SWARNING
The torque setting is given by the preloading meas-
urement on bearings.

F28084
 Copyright ©

SECTION 27 - REAR AXLE 77

Carry out the preloading measurement (P) of the

pinion taper roller bearings, using a dynamometer
380002672.
The adjustment is carried out by increasing the ring
nut torque setting gradually, being careful not to ex-
ceed.
Once you got the requested preloading value, caulk
the ring nut.

F28098
 Copyright ©

78 SECTION 27 - REAR AXLE

TOE-IN/STEERING ANGLE ADJUSTMENT

1 2 3 3 2 1

5 5

4 4

F28099

Toe-in

Put two equal one-metre-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.

SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340

Measure the distance in mm (M) between the bars

ends with a tapeline.

NOTE: keep the minimum value, swinging the

measurement point.

F27341
 Copyright ©

SECTION 27 - REAR AXLE 79

Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter
nominal toe-in= A-2 → measured toe-in= M-5
A

M -05

F27342

If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1

F27343

After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested torque.
1 2

F27344
 Copyright ©

80 SECTION 27 - REAR AXLE

Steering angle

Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.

F27345

Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.

F27346

Adjust the mechanical steering stop, screwing in or

out the stop screw (4), locking it with the locknut (5)
to the requested tightening torque.

5 4

F27347

Steer completely towards the other side and repeat

the same operations.

F27348
 Copyright ©

SECTION 27 - REAR AXLE 81

2.3 FAULT FINDING

PROBLEMS CAUSE

1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise

1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.

2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with bigger
radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both tyres.

4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.

5. Bent half shaft

Replace half shaft.

6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.

7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.

8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings etc.
Replace whenever necessary.

9. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.

10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.

11. Incorrect use of the product

See the vehicle producer’s instructions once again.

82
PROBLEM
Ring gear tooth broken on the
outer side
Ring gear tooth broken side
Pinion or ring gear teeth worn
Overheated ring and pinion teeth
See if gear teeth have faded
Pinion teeth pitting
Axle beam body bent
Worn out or pitted bearings
Oil leakage form gaskets and
seals
Excessive wearing out of input
flange spline
Fatigue failure of pinion teeth
See if the fracture line is well
defined
(wave lines, beach lines)
Pinion and ring teeth breakage
SECTION 27 - REAR AXLE
CAUSE
Excessive gear load compared to
the one foreseen
Incorrect gear adjustment
(excessive backlash)
Pinion nut loose
Load bump
Incorrect gear adjustment
(insufficient backlash)
Pinion nut loose
Insufficient lubrication
Contaminated oil
Incorrect lubrication or depleted
additives
Worn out pinion bearings that
cause an incorrect pinion axle
backlash and wrong contact
between pinion and ring
Prolonged functioning at high
temperatures
Incorrect lubrication
Low oil level
Contaminated oil
Excessive use
Insufficient lubrication
Vehicle overloaded
Vehicle’s accident
Load bump
Insufficient lubrication
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Prolonged functioning at high
temperature of the oil
Oil gasket assembled incorrectly
Seal lip damaged
Contaminated oil
Exhaustive use
Pinion nut loose
Pinion axle backlash
Exhaustive use
Continuous overload
Crash load of differential
components
Copyright ©
ACTION
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Replace bevel gear set.
Follow carefully the recommended
operations for the adjustment of
bevel gear set backlash.
Use correct lubricants, fill up to the
right levels and replace according to
the recommended program.
Replace bevel gear set.
Use proper lubrication, fill up to right
level and replace at recommended
program.
Replace bevel gear set.
Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Replace axle beam body.
Replace bearings.
Use correct lubrication, fill up to the
right level and replace at
recommended intervals.
Replace the gasket or seal and
matching surface if damaged.
Use correct lubrication and replace
at recommended intervals.
Replace the flange.
Check that the pinion spline is not
excessively worn out.
Replace bevel gear set if required.
Replace bevel gear set.
Check and/or replace other
differential components.

Side gear spline worn out
Replace all scratched washers
(Excessive backlash)
Thrust washer surface worn out
or scratched
Inner diameter of tapered roller
bearing worn out
Bent or broken half shaft
Half shaft broken at wheel side
SECTION 27 - REAR AXLE
Excessive use
Insufficient lubrication
Incorrect lubrication
Contaminated oil
Excessive use
Excessive pinion axial backlash
Insufficient lubrication
Contaminated oil
Vehicle intensively operated or
overloaded
Wheel support loose
Beam body bent
Copyright ©
83
Replace differential gear group.
Replace half shaft if required.
Use correct lubrication and fill up to
right level.
Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm thickness lower
than the new ones.
Replace bearing.
Check pinion axial backlash.
Use proper lubrication, fill up to right
level and replace at recommended
intervals.
Replace.
Replace.
Check that wheel support is not
worn out or wrongly adjusted.
 Copyright ©

84 SECTION 27 - REAR AXLE

3. SPECIAL TOOLS

P/N CNH APPLICATION 2WS 4WS

380000406 Disassembly/Assembly of differential ring nuts / •
380000816 Planetary carrier disassembly • /
380000986 + Disassembly bearing cups from the axle housing • /
380000987
380000990 Axle housing lifting • /
380000991 Bearings pre-load measurement • /
380002213 Assembly of seal ring of the swivel housing / •
380002215 Assembly of pinion bearing outer cup / •
380002218 Disassembly/Assembly of pinion ring nut / •
380002222 Assembly of bearing cups in the wheel hub / •
380002226 Assembly of bushing in the half-beam / •
380002667 Assembly of bushings in the crown retaining hub / •
380002668 Assembly of bushing in the swivel housing / •
380002669 Assembly of seal ring in the swivel housing / •
380002670 Assembly of seal ring in the half-beam / •
380002671 Assembly of differential bearing cups / •
380002672 Preload measure of pinion bearing / •
380002673 Measurement of pinion shims / •
380002674 Measurement of pinion shims / •
380002675 Connection flange disassembly • /
380002676 Disassembly bearing of wheel carrier hub shaft • /
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 33 - BRAKES SYSTEM

1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT .............................................................................................................. 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK....................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
 Copyright ©

2 SECTION 33 - BRAKES SYSTEM

 Copyright ©

SECTION 33 - BRAKES SYSTEM 3

1. TECHNICAL SPECIFICATIONS
2WS

BRAKES OPERATION HYDRAULIC

Brakes Wet disc, piston operated
Oil brake Akcela LHM
Number discs (on side) 4
Brakes disc total friction area 1440 cm2

4WS

BRAKES OPERATION HYDRAULIC

Brakes Wet disc, piston operated
Oil brake Akcela LHM
Number discs (on side) 3
Brakes disc total friction area 1440 cm2

The loader backhoe has two braking systems:

a hand operated brake, that incoporates two free
floating friction pads;
hydraulically operated inboard wet disc brakes in the
rear axle.
The hand brake, when pulled, locks the brake disc on
the rear of the transmission.
Operation of the foot brake, instead, pressurizes the
brake fluid in the master cylinders which feeds the
brake pistons in the axle housing. The brake pistons
then compress the brake friction discs and separa-
tion discs, which locks the axle shaft to the axle
housing.
 Copyright ©

4 SECTION 33 - BRAKES SYSTEM

BRAKE SYSTEM LAYOUT (2WS)

1. Brake piston assembly 5. Master cylinders

2. Brake discs 6. Hand brake
3. Brake tank 7. Axle shaft
4. Pressure switch
 Copyright ©

SECTION 33 - BRAKES SYSTEM 5

BRAKE SYSTEM LAYOUT (4WS)

1. Brake piston assembly 5. Master cylinders

2. Brake discs 6. Hand brake
3. Brake tank 7. Axle shaft
4. Pressure switch
 Copyright ©

6 SECTION 33 - BRAKES SYSTEM

2. HAND BRAKE
The hand brake is fitted to all models and incorpo-
rates two free floating friction pads.
When operated the cam (1) forces the friction pads
against the disc (2), effecting a braking action on the
output shaft from the transmission, locking the drive
shaft to the rear and front axles.

19

20
3

19

2 18

1
17
21

15
16
14

12 13

11

10

9
8
7
6
5
4
F27750

1. Screw-brake mounting 12. Id seal

2. Assembly-caliper 13. Bearing
3. Nut-brake mounting screw 14. Retainer
4. Adjustment nut 15. Cam
5. Adjustment nut 16. Torque plate-front
6. Washer 17. Carrier and lining assembly
7. Washer 18. Torque plate-rear
8. Washer-thrust 19. Sleeve mounting
9. Lever 20. Adjusting screw
10. Boot 21. Spring
11. Cam
 Copyright ©

SECTION 33 - BRAKES SYSTEM 7

2.1 HAND BRAKE ADJUSTMENT

The hand brake is located on the transmission output

shaft on 4x4 transmission and rear axle on the 4x2
transmission.
The 4x2 transmission hand brake is located on the
rear axle brake disc splined to pinion shaft (1), hy-
draulic oil filter (2), hand brake cable (3), hand brake
caliper (4).

When refitting the caliper unit (2) insert the two

screws (1) through the caliper; it will be necessary to
apply Loctite 270 to the locknuts (3). Tighten the
screws while holding the locknuts. Once the screws
are tightened, torque the nuts to 150 Nm. Ensure that
the tubes can move.

Adjust the clearance between the brake pads and

disc to 0.5 mm using the nut and locknut (1).

Adjust the cable clevis and lock the nut (1) to get 4 to
5 clicks on the hand brake lever.
 Copyright ©

8 SECTION 33 - BRAKES SYSTEM

3. BRAKE CYLINDERS
Brake cylinders are accessible from the engine com-
partment.
The brake cylinders are linked by a balancing pipe
(12) situated below the cylinders to maintain equal oil
pressure between the two cylinders.

1. Fitting 7. Seal
2. Pressure switch 8. Clevis
3. Fitting 9. Seals
4. Body 10. Secondary spool
5. Primary spool 11. Spring
6. Bottom 12. Balancing pipe
 Copyright ©

SECTION 33 - BRAKES SYSTEM 9

MASTER CYLINDER WITH BRAKES RELEASED

1 2 3 4 5 6

10

9 8 7
F29371

Trapped oil
Tank oil (no pressure)

1. Oil to cylinder (right hand side) 6. Cylinder body

2. Pressure switch 7. Cylinder body
3. Secondary spool 8. Primary spool stop
4. Tank inlet 9. Balancing pipe
5. Primary spool 10. Oil to cylinder (left hand side)

With the brakes released the brake lines are open to

the tank to allow the brakes to release. The cylinders
are also open to tank through the centre of the valve.
 Copyright ©

10 SECTION 33 - BRAKES SYSTEM

CYLINDER WITH BRAKE PEDALS DEPRESSED

1 2 3 4 5 6

10

9 8 7
F29372

Pressurized brake oil

Tank oil (no pressure)

1. Oil to cylinder (right hand side) 6. Cylinder body

2. Pressure switch 7. Cylinder body
3. Secondary spool 8. Primary spool stop
4. Tank inlet 9. Balancing pipe
5. Primary spool 10. Oil to cylinder (left hand side)

As the brake pedals are depressed initial movement

of the cylinder piston closes the centre port to isolate
the tank.
Further piston movement creates brake oil pressure
to apply the brakes. The pressure ports are both
open as the two seals on both cylinders have ex-
posed the two ports, therefore allowing equal pres-
sure in both cylinders.
 Copyright ©

SECTION 33 - BRAKES SYSTEM 11

CYLINDER WITH ONE BRAKE PEDAL DEPRESSED

1 2 3 4 5 6

10

9 8 7
F29373

Pressurized brake oil

Tank oil (no pressure)

1. Oil to cylinder (right hand side) 6. Cylinder body

2. Pressure switch 7. Cylinder body
3. Secondary spool 8. Primary spool stop
4. Tank inlet 9. Balancing pipe
5. Primary spool 10. Oil to cylinder (left hand side)

When using one brake to assist turning, the brake

cylinder being applied operates only one brake. This
is achieved by the pressure port being blocked by the
two seals on the cylinder not being operated.
 Copyright ©

12 SECTION 33 - BRAKES SYSTEM

Discs and piston layout

1. Steel plates
2. Outer housing
3. Seals
4. Piston
5. Friction plates
6. Outer housing

Piston and seals

1. Piston
2. Fitting
3. Outer housing

The brakes are supplied oil from the brake pedal

tank and into the axle by tubes into each half axle
through the fitting (2) which is sealed to the piston by
two O-rings.

When the fitting (2) is removed ensure the O-rings

are replaced with new.
 Copyright ©

SECTION 33 - BRAKES SYSTEM 13

4. OIL BRAKE TANK

1. Oil brake tank
2. Low level switch

NOTE: depressing the low level switch test button

mounted in the middle of the brake filler tank cap, the
warning light circuit can be tested. The light that is il-
luminated is the handbrake warning light mounted on
the right hand instrument console, ensure hand-
brake is in the “off” position.

5. BLEEDING PROCEDURE
1. Oil brake tank is full (1)

2. Open left hand brake bleed valve (2)

3. Press repeatedly on both brake pedals (3) to

purge the system
4. Hold pedals down
5. Lock bleed valve (2)
6. Release pedals
7. Repeat steps 4-6
8. Repeat steps 2-6 on right hand brake
9. Test brakes repeat if necessary

NOTE: when the brake pedals are operated, both to-

gether, the electrical supply to the front wheel drive
switch is cut allowing the clutch to de-energize thus
engaging the front wheel drive, providing four wheel
braking.
 Copyright ©

14 SECTION 33 - BRAKES SYSTEM

NOTE:
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 35 - HYDRAULIC SYSTEM

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3

1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 3
1.2 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT PILOT MODELS ...................................................... 5
1.3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .............................................................. 8
1.4 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT MECHANICAL MODELS ....................................... 11
1.5 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS............................................... 13
1.6 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT PILOT MODELS .................................................... 15
1.7 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODEL .............................................................. 18
2. HYDRAULIC PUMP.................................................................................................................................... 21
2.1 DESCRIPTION AND OPERATION...................................................................................................... 21
2.2 TECHNICAL SPECIFICATIONS.......................................................................................................... 22
2.3 LOAD SENSING VALVE ..................................................................................................................... 24
2.4 REMOVAL ........................................................................................................................................... 26
2.5 COMPONENTS ................................................................................................................................... 27
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 28
3. CONTROL VALVES ................................................................................................................................... 32
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 32
3.2 CONTROL VALVES “REXROTH” (PILOT MODELS) ......................................................................... 48
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 71
4.1 DESCRIPTION AND OPERATION...................................................................................................... 71
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 72
4.3 PRECISION SWING CONTROL ......................................................................................................... 74
5. HYDRAULIC CYLINDERS.......................................................................................................................... 77
5.1 LOADER CYLINDER ........................................................................................................................... 78
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 83
5.3 4X1 BUCKET CYLINDER.................................................................................................................... 87
5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 90
5.5 BACKHOE DIPPER CYLINDER.......................................................................................................... 94
 Copyright ©

2 SECTION 35 - HYDRAULIC SYSTEM

5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 98

5.7 SHORT AND LONG TELESCOPIC CYLINDER................................................................................ 102
5.8 STABILIZER CYLINDER (CENTRE PIVOT - 4WS) .......................................................................... 106
5.9 STABILIZER CYLINDER (SIDESHIFT) ............................................................................................. 110
5.10 SWING CYLINDER.......................................................................................................................... 114
5.11 BACKHOE SIDESHIFT LOCKING CYLINDER (SIDESHIFT) ......................................................... 118
5.12 SPECIAL TOOLS............................................................................................................................. 120
6. HYDRAULIC CONTROL LEVERS............................................................................................................ 121
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 121
6.2 DESCRIPTION AND OPERATION.................................................................................................... 122
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 125
6.4 HYDRAULIC CONTROL LEVER VALVE .......................................................................................... 128
7. FAULT FINDING AND FLOW TESTING .................................................................................................. 131
7.1 PRELIMINARY CHECKS................................................................................................................... 131
7.2 FAULT FINDING ................................................................................................................................ 132
7.3 PRESSURE TESTING....................................................................................................................... 136
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 3

1. HYDRAULIC DIAGRAMS
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS

LS

P
T
5 4 3 6

T2

P2
DIAGNOSTIC A B
BULKHEAD

M
T1
C2 Pil Pil C2 C2 Pil Pil C2

1
C C C C

C2 C1
V V V V
V2 Pil Pil V2 V2 Pil Pil V2
MX
P2
V2 V1

B1
X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3
22

A1
P1

A
T
b b b

L R

T
7
T

B
V2 C2

B2
BL

a a

A2
A
Pil

a
21

T
T3

T T T
B A A

T
LOADER
CONTROL

B3
B
VALVE
20

A3
A
T
T

B4
B
B
E
19

A4
P
P LS T
T

2
13

T
T

P
V2 C2

B E

A5 B5
BL

18

B
12 Pil

V2 C2

A6 B6
V1 C1
17

V1 C1
EF CF LS

A7 B7
V2 C2

16

T
AIR OUT 0.35±0.06

8
AIR IN 0.03±0.008

B8
B

A8
A
T
15

C
11

T3
10
14

9
F30298
 Copyright ©

4 SECTION 35 - HYDRAULIC SYSTEM

1. Front axle
2. Steering control valve
3. 4x1 bucket cylinder
4. Loader bucket cylinder
5. Loader cylinder
6. Ride control valve
7. Loader control valve
8. Pump
9. Oil cooler
10. Oil filter
11. Return
12. Hand hammer
13. Backhoe hammer
14. Backhoe control valve
15. Sideshift cylinders
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 5

1.2 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT PILOT MODELS

1 2

P P
T T

6
1 3 2 4 1 3 2 4

3 4 5

T1 T2

A B T B T B T A B T A B T T A
T T T

T3
T C
B1
A1

2
3

4
1

B3
A3

B2
A2

2
3

4
1

B4
A4
T1

LS

D B
2
P

A
ACC

P
DIAG

A8 B8 A7 B7 A6 B6 A5 B5 A4 B4 A3 B3 A2 B2 A1 B1 M P2
1

7
J

E
A

B
3

V1 V2

12 14
11
C

10
5

V1 V2
C1 C2

13
G

H
7

C1 C2
E

9
7

F27502
 Copyright ©

6 SECTION 35 - HYDRAULIC SYSTEM

B
25
22 23 24 A B

20

19 C2 C1

MX
P2
V2 V1

X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3

P1

b b b

L R

26
a a
a
T3

T T T
B A A

B
E

P
P LS T
T
21 27
28
C

T
P

B E

EF CF LS

15
AIR OUT 0.35±0.06
AIR IN 0.03±0.008

18
16 17

F27503
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 7

1. Left hand joystick

2. Right hand joystick
3. Backhoe lifting and digging control
4. Swing control
5. Backhoe digging and lifting control
6. Backhoe bucket control
7. Backhoe control valve
8. Stabilizers right cylinder
9. Stabilizers left cylinder
10. Backhoe digging cylinder
11. Bucket cylinder
12. Swing cylinder
13. Backhoe lifting cylinder
14. Telescopic cylinder
15. Pump
16. Oil cooler
17. Oil filter
18. Return
19. Front axle
20. Diagnostic
21. Steering control valve
22. Loader cylinder
23. Loader bucket cylinder
24. Bucket 4x1 cylinder
25. Ride control valve
26. Loader control valve
27. Hand hammer
28. Backhoe hammer
 Copyright ©

8 SECTION 35 - HYDRAULIC SYSTEM

1.3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS

1 2

P P
T T

1 3 2 4 1 3 2 4

3 4 5 6

T1 T2

A B T B T B T A B T A B T T A
T T T

T3
T C
B1
A1

2
3

4
1

B3
A3

B2
A2

2
3

4
1

B4
A4
T1

LS

D B
2
P

A
ACC

P
DIAG

C A8 B8 A7 B7 A6 B6 A5 B5 A4 B4 A3 B3 A2 B2 A1 B1 M P2
1

7
J

BL

V2
E
A

T
3

BL

V2
Pil

T
C2
V1 V2

Pil
11 12 14
C

C2
5

15 C1 C2
G

H
7

V1 V2
10
E

F
7

C1 C2 13

F30299
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 9

B
24 25
22 23 x1 A B

20
C2 Pil Pil C2 C2 Pil Pil C2
C C C C
19 V V V V
C2 C1

V2 Pil Pil V2 V2 Pil Pil V2

MX
P2
V2 V1

X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3

P1

b b b

L R

a a
a
T3

T T T
B A A

26

B
E

P
P LS T
T

21 27 28
C

T
P

B E

EF CF LS

AIR OUT 0.35±0.06

15 AIR IN 0.03±0.008

18
17

16
F30300
 Copyright ©

10 SECTION 35 - HYDRAULIC SYSTEM

1. Left hand joystick

2. Right hand joystick
3. Backhoe lifting and digging control
4. Swing control
5. Backhoe digging and lifting control
6. Backhoe bucket control
7. Backhoe control valve
8. Stabilizers right cylinder
9. Stabilizers left cylinder
10. Backhoe digging cylinder
11. Bucket cylinder
12. Swing cylinder
13. Backhoe lifting cylinder
14. Telescopic cylinder
15. Sideshift cylinders
16. Oil cooler
17. Oil filter
18. Return
19. Front axle
20. Diagnostic
21. Steering control valve
22. Loader cylinder
23. Loader bucket cylinder
24. Bucket 4x1 cylinder
25. Ride control valve
26. Loader control valve
27. Hand hammer
28. Backhoe hammer
29. Pump
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 11

1.4 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT MECHANICAL MODELS

LS

P
T
A B
8
7

T2

P2
a b 5 6
A B

M
a b 3

T1
P T C2 P il P il C2 C2 P il P il C2

2
C C C C

C2 C1
V V V V
V2 P il P il V2 V2 P il P il V2
MX
P2
V2 V1

X2 T

B1
M1 M2 LS B1 A1 B2 A2 B3 A3

A1
P1

A
22

T
b b b

L R

T
T

B
V2 C2

B2
BL

a a

A2
A
P il

a
21

T
T3

T T T
B A A

T
9 20

B3
B

A3
A
T
T

B4
B
B
E

A4
P
P LS T

4
T
19
10
11

T
18
T

T
P
V2 C2

B E BL

B5
B

A5
P il

C2
V2
A6 B6

C1
V1
EF CF LS 17

B7
A7

V2

C2
12 16

V1

C1
AIR 0.03±0.008

AIR 0.35±0.06

B8
B

A8
A
T
23
15
13 14

F30301
 Copyright ©

12 SECTION 35 - HYDRAULIC SYSTEM

1. Rear axle
2. Front axle
3. Diagnostic
4. Steering control valve
5. Loader cylinder
6. Loader bucket cylinder
7. Bucket 4x1 cylinder
8. Ride control valve
9. Loader control valve
10. Hand hammer
11. Backhoe hammer
12. Pump
13. Oil cooler
14. Oil filter
15. Return
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Backhoe bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
23. Backhoe control valve
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 13

1.5 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS

LS

P
T
A B 7 8

T2

P2
a b 5 6 4x1-6x1 A B

M
a b 3

T1
P T C2 Pil Pil C2 C2 Pil Pil C2
C C C C

2 V V V V
C2 C1

V2 Pil Pil V2 V2 Pil Pil V2

MX
P2
V2 V1

B1
X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3
22

A1
P1

A
T
b b b

L R

T
T

B
V2 C2

B2
BL

a a 21

A2
A
Pil

T
T3

T T T
B A A

B3
20

A3
A
T
T

B4
B
B
19

A4
P
P LS T
T

4 10 11

T
T

P
V2 C2

E
B
18

A5 B5
BL

B
Pil

V2 C2

A6 B6
V1 C1
17

V1 C1
EF CF LS

A7 B7
V2 C2

16

T
12
AIR OUT 0.35±0.06
AIR IN 0.03±0.008

BI-DIR AUX
A8 B8
B
A
T
24

C
15
14

T3
23

13
F30302
 Copyright ©

14 SECTION 35 - HYDRAULIC SYSTEM

1. Rear axle
2. Front axle
3. Diagnostic
4. Steering control valve
5. Loader cylinder
6. Loader bucket cylinder
7. Bucket 4x1 cylinder
8. Ride control valve
9. Loader control valve
10. Hand hammer
11. Backhoe hammer
12. Pump
13. Oil cooler
14. Oil filter
15. Return
16. Stabilizers right cylinder
17. Stabilizers left cylinder
18. Backhoe digging cylinder
19. Backhoe bucket cylinder
20. Swing cylinder
21. Backhoe lifting cylinder
22. Telescopic cylinder
23. Backhoe control valve
24. Sideshift cylinders
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 15

1.6 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT PILOT MODELS

1 2

P P
T T

3 2 4
6
1 1 3 2 4

3 4 5

T1 T2

A B T B T B T A B T A B T T A
T T T

T3
T C
B1
A1

2
3

4
1

B3
A3

B2
A2

2
3

4
1

B4
A4
T1

LS

D B
2
P

A
ACC

P
DIAG

A8 B8 A7 B7 A6 B6 A5 B5 A4 B4 A3 B3 A2 B2 A1 B1 M P2
1

7
J

BL

V2
E
A

T
3

V1

BL
V2

V2
Pil
14

T
C2

Pil
11 12
C

C2
5

V1 V2
C1 C2
G

H
7

C1 C2

10
E

9 13
7

F27426
 Copyright ©

16 SECTION 35 - HYDRAULIC SYSTEM

15 B
A B 22
a b 19 20 21 A B

a b 17
P T C2 P il P il C2 C2 P il P il C2
C C C C
16 C2 C1
V V V V
V2 P il P il V2 V2 P il P il V2
MX
P2
V2 V1

X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3

P1

b b b

L R

a a
a
T3

T T T
B A A

23

B
E

P
P LS T
T
18 24 25
C

T
P

B E

EF CF LS

26
E
AIR 0.03±0.008

AIR 0.35±0.06

29
27 28

F28114
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 17

1. Left hand joystick

2. Right hand joystick
3. Backhoe lifting and digging control
4. Swing control
5. Backhoe digging and lifting control
6. Backhoe bucket control
7. Backhoe control valve
8. Stabilizers right cylinder
9. Stabilizers left cylinder
10. Backhoe digging cylinder
11. Backhoe bucket cylinder
12. Swing cylinder
13. Backhoe lifting cylinder
14. Telescopic cylinder
15. Rear axle
16. Front axle
17. Diagnostic
18. Steering control valve
19. Loader cylinder
20. Loader bucket cylinder
21. Bucket 4x1 cylinder
22. Ride control valve
23. Loader control valve
24. Hand hammer
25. Backhoe hammer
26. Pump
27. Oil cooler
28. Oil filter
29. Return
 Copyright ©

18 SECTION 35 - HYDRAULIC SYSTEM

1.7 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODEL

1 2

P P
T T

1 3 2 4 1 3 2 4

3 4 5 6

7
T1 T2

A B T B T B T A B T A B T T A
T T T

T3
T C
B1
A1

2
3

4
1

B3
A3

B2
A2

2
3

4
1

B4
A4
T1

LS

D B
2
P

A
ACC

P
DIAG

C A8 B8 A7 B7 A6 B6 A5 B5 A4 B4 A3 B3 A2 B2 A1 B1 M P2
1

BI-DIR AUX
J

BL

V2
E
A

T
3

BL

V2
Pil

T
C2
V1 V2

Pil
11 12 14
C

C2
5

15 C1 C2
G

H
7

V1 V2
10
E

F
7

C1 C2 13

F30303
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SECTION 35 - HYDRAULIC SYSTEM 19

B
16
A B 21 22
a b 19 20 4x x1 A B

a b 30
P T C2 Pil Pil C2 C2 Pil Pil C2
C C C C
17 V V V V
C2 C1

V2 Pil Pil V2 V2 Pil Pil V2

MX
P2
V2 V1

X2 T
M1 M2 LS B1 A1 B2 A2 B3 A3

P1

b b b

L R

a a
a
T3

T T T
B A A

23

B
E

P
P LS T
T

18 24 25
C

T
P

B E

EF CF LS

AIR OUT 0.35±0.06

26 AIR IN 0.03±0.008
E

19
28

27
F30304
 Copyright ©

20 SECTION 35 - HYDRAULIC SYSTEM

1. Left hand joystick

2. Right hand joystick
3. Backhoe lifting and digging control
4. Swing control
5. Backhoe digging and lifting control
6. Backhoe bucket control
7. Backhoe control valve
8. Stabilizers right cylinder
9. Stabilizers left cylinder
10. Backhoe digging cylinder
11. Backhoe bucket cylinder
12. Swing cylinder
13. Backhoe lifting cylinder
14. Telescopic cylinder
15. Sideshift cylinders
16. Rear axle
17. Front axle
18. Steering control valve
19. Loader cylinder
20. Loader bucket cylinder
21. Bucket 4x1 cylinder
22. Ride control valve
23. Loader control valve
24. Hand hammer
25. Backhoe hammer
26. Pump
27. Oil cooler
28. Oil filter
29. Return
30. Diagnostic
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 21

2. HYDRAULIC PUMP
2.1 DESCRIPTION AND OPERATION

There are two types of hydraulic pump:

- for engine 95HP
- for engine 110HP.

The gear type hydraulic pump assembly is mounted

on the rear of the transmission and driven by a shaft
directly connected to the engine flywheel splined to
the torque converter housing.
The pump comprises of two pumping elements, the
front pump (1) rear pump (2) and load sensing
steering flow divider control valve (3).
Oil is drawn through the common inlet port into both
pumping elements.
Front pump flow is directed to the loader and
backhoe control valves and sideshift clamping
system.
Rear pump flow passes through the flow divider
valve which maintains priority oil flow to the steering
system with remaining flow directed for operation of
stabilizers, loader and backhoe elements.
 Copyright ©

22 SECTION 35 - HYDRAULIC SYSTEM

2.2 TECHNICAL SPECIFICATIONS

PUMP (ENGINE 95HP) 1st PUMP 2nd PUMP

Direction of rotation (looking on drive shaft) Clockwise (D)
Displacement 35.427 (cm3/rev) 35.427 (cm3/rev)
Inlet pressure range for pump 0.7 ÷ 3 bar
Maximum continuos pressure P1 260 bar 260 bar
Maximum intermittent pressure P2 280 bar 280 bar
Maximum peak pressure P3 300 bar 300 bar
min P1 350 (min-1)
Speed
max P1 3000 (min-1)
Operating temperature -25 to -80 (°C)
recommended 12 to 100 mml 2/s
Viscosity range
permitted max 750 mml 2/s
Dp > 200 bar 8 - Nas 1638
bx = 75 - 10 mm 19 / 17 /14 - ISO 4406
Contamination class
Dp < 200 bar 10 - Nas 1638
bx = 75 - 25 mm 21 / 19 /16 - ISO 4406
Relief valve 177 ± 3 bar
Stand by pressure load sensing valve 7 bar
Weight 30 kg

PUMP (ENGINE 110HP) 1st PUMP 2nd PUMP

Direction of rotation (looking on drive shaft) Clockwise (D)
Displacement 40.258 (cm3/rev) 35.427 (cm3/rev)
Inlet pressure range for pump 0.7 - 3 bar
Maximum continuos pressure P1 260 bar 260 bar
Maximum intermittent pressure P2 280 bar 280 bar
Maximum peak pressure P3 300 bar 300 bar
Operating temperature -25 to -80 (°C)
min P1 350 (min-1)
Speed
max P1 3000 (min-1)
recommended 12 to 100 mml 2/s (cSt)
Viscosity range
permitted max 750 mml 2/s (cSt)
Dp > 200 bar 8 - Nas 1638
bx = 75 - 10 mm 19 / 17 /14 - ISO 4406
Contamination class
Dp < 200 bar 10 - Nas 1638
bx = 75 - 25 mm 21 / 19 /16 - ISO 4406
Relief valve 177 ± 3 bar
Stand by pressure load sensing valve 7 bar
Weight 30 kg
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 23

TIGHTENING TORQUES

HYDRAULIC DIAGRAM
 Copyright ©

24 SECTION 35 - HYDRAULIC SYSTEM

2.3 LOAD SENSING VALVE

1. Orifice 8. Steering relief valve

2. Backhoe circuits (EF) 9. Relief valve adjuster
3. Filter 10. Poppet
4. Spool 11. Return to inlet pump port
5. To steering priority flow (CF) 12. Lock plug
6. Orifice 13. Load sensing signal (LS)
7. Inlet port from rear pump (IN) 14. Orifice

When the steering is in neutral the LS port is

connected to the unload (through the steering) and
the steering inlet port (CF) is open.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 25

2 7

6
F29457

Load sensing valve with pump running - Steering in neutral

Return to tank oil
Trapped oil
Pressure oil
1. Orifice 5. To steering priority flow (CF)
2. Backhoe circuits (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool

The pressure on (CF) increases until the pressure value (standby pressure) is sufficient to move the spool valve
in a way to divert the flow toward (EF).

2 7

6
F29458

Load sensing valve with pump running - Steering working

Trapped oil
Return to tank oil
1. Orifice 5. To steering priority flow (CF)
2. Backhoe circuits (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool

During steering two actions are performed:

1. The fluid moves to the steering through (CF).
2. The (LS) signal is in communication to the steering.
 Copyright ©

26 SECTION 35 - HYDRAULIC SYSTEM

2.4 REMOVAL

1. Drain hydraulic tank into a container capable of

holding up to 75 litres.

2. Disconnect handbrake cable and transmission

to rear axle drive shaft.

3. Disconnect and plug pump inlet and pressure

hoses.
Remove pump flange mounting screws and
remove pump.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 27

2.5 COMPONENTS

1. Retaining screw 19. Bushing

2. Steering control valve 20. Gasket
3. Spool 21. Bushing
4. O-ring 22. Back-up seal
5. Plug / Cap 23. Bearing block
6. Valve 24. Pump gear
7. Filter 25. Gear
8. Connector 26. Front pump using
9. Spring seat 27. Gasket
10. Spring 28. Gear
11. O-ring 29. Flange
12. Cap 30. Seal
13. Relief valve 31. Seal
14. O-ring 32. Snap ring
15. Poppet 33. Pressure seal (rubber)
16. Spring 34. Pump gear
17. Seat 35. O-ring
18. Rear pump housing 36. Screw
 Copyright ©

28 SECTION 35 - HYDRAULIC SYSTEM

2.6 DISASSEMBLY AND ASSEMBLY

DISASSEMBLY STEERING CONTROL VALVE

To aid reassembly draw an alignment line along the
total length of the pump assembly.
Remove retaining screws (1).

Remove the load sensing steering control valve (2).

Check and eventually replace the O-rings (35).

DISASSEMBLY STEERING CONTROL VALVE

Do not disassemble the steering system relief valve
(A) if the steering circuit relief valve pressure was to
specification when pressure testing the pump prior
to overhaul.

NOTE: if the steering system relief valve is

disassembled then the valve must be reset as
described in the trouble shooting pressure and flow
testing chapter before the vehicle is
recommissioned.

Wash all components in an approved degreasant

and inspect for the following.
Valve bore must be free from scoring and damage to
metering edges.
The spool (3) should slide freely in the bore and be
free of scoring and damage.
Ensure all orifices are clean.
The relief valve seat should be free from pitting and
damage. A small chamfer on the mouth of the bore
is permissible.
Examine the filter (7) which fit inside the unload and
relief valves. The filter must be replaced if
contaminated.
Pressure and flow test the pump.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 29

DISASSEMBLE REAR PUMP

Remove the screws (36).

Remove the rear pump assembly (18).

IMPORTANT: prior to disassembly and to ensure

correct reassembly identify the position of each
bearing block in the pump body as described below.

Scribe an identifying letter “A” and “B”, “C” and “D”

on the pump housing and in the channel of each
bearing block.

NOTE: orientation of bearing block seals relative to

oil port.

If scribe is not available take care to keep bearing

blocks in pairs.
Disassemble gears (24), seals (22) and (33) and
bearings (23).
Wash all components in approved degreasant.
 Copyright ©

30 SECTION 35 - HYDRAULIC SYSTEM

Inspect the wear track cut by the gears in pump

body. The body can be reused if the track is bright
and polished and does not exceed 0.08 mm - 0.0031
inch (0.076 mm - 0.0030 inch) in depth.
Examine bearing block faces for scoring and
flatness paying particular attention to the face which
abuts the gears.
Examine bearing block bushes for scoring.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.

If pump block, gears or bearing blocks are worn and

require replacement the pump assembly must be
replaced.
Reassembly follows the disassembly procedure in
reverse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed using identification
letters scribed during disassembly.
Z Ensure plastic back-up seals are correctly
positioned in the rubber seal.

DISASSEMBLY FRONT PUMP

To remove from the pump assembly (26) from the
flange (29) it’s necessary to remove the snap ring
(33).
Remove and replace flange seals (31) and (32).

Identify and note the position of each bearing block

to ensure correct reassembly.
Disassemble gears (28) and (34), seals (22) and
(33) and bearings (23).
Wash all components in approved degreasant.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 31

Inspect the wear track cut by the gears in the inlet

side of the pump body. The body can be reused if
the track is bright and polished and does not exceed
0.15 mm in depth.
Examine bearing block faces for scoring.
Inspect PTFE coated bearings in body or flange for
wear. If bearings are worn the bronze backing will be
revealed.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
Examine flange seal contact area on driveshaft. If
pump block, gears, bearing blocks or drive shaft are
worn the pump assembly must be replaced.

Reassemble using disassembly procedure in

reverse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed.
Z Ensure back-up seals are correctly positioned in
the seal.

Assemble inner flange seal, (31), with spring and lip

facing into pump. Install outer seal, (32), with garter
spring and lip facing outwards and refit circlip (33).
Coat seals with high melting point grease.

NOTE: ensure seals are fitted back to back.

NOTE: if the seal recess has been scored during

seal removal coat outside diameter of seal with
flexible gasket sealant to prevent leakage.
 Copyright ©

32 SECTION 35 - HYDRAULIC SYSTEM

3. CONTROL VALVES
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS)

The hydraulic circuit is a load sensing flow sharing Loader control valve
system working in conjunction with a fixed The loader control valve is mounted on the right
displacement gear type hydraulic pump. hand side of the machine adjacent to the pump.
This system has the advantage that at any time the The valve assembly consists of a maximum of three
distribution of flow to the services being operated is spool operated sections and provides oil flow to the
in proportion to the openings of the control valve loader boom, bucket and auxiliary services where
spools. fitted.
The flow distribution to the backhoe and loader
control valves is independent of the load and it is Backhoe control valve
therefore possible to operate two or more spools The backhoe control valve is located at the rear of
satisfactorily at the same time. the chassis.
The principal components of the load sensing flow The control valve consists of a maximum of seven
sharing system are the pressure compensator sections of spool control valves and provides the oil
valves in each control valve section, together with flow for operating the lifting, the digging, the bucket,
the load sense line which connects all the spool the stabilizers, the swing and telescopic arm
sections in both the loader and backhoe control (optional).
valve assemblies.
Because the hydraulic pump is a fixed displacement
gear type pump it should be noted that the load
sense line only connects the loader and backhoe
control valve assemblies and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and flow
from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
Flow from the rear section of the pump passes
through the load sensing flow divider valve mounted
on the pump and gives priority flow to the steering
circuit with remaining flow directed to supplement
the flow from the front pump for the loader and
backhoe circuits.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply circuit is controlled by the
pump flow balancer valve in accordance with the
pressure in the load sense line.
Consequently the higher the load sense pressure
the less flow is returned to tank with corresponding
increase in flow/pressure to the hydraulic circuits.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure
in the load sense line when it reaches 210 bar.
Because the pump flow balancer valve is influenced
by load sense pressure the valve diverts sufficient
flow back to tank to maintain the maximum system
pressure of 210 bar.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 33

Hydraulic circuit oil

Steering circuit oil
Loader sense oil
Suction oil
Return to tank

1. Oil tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
3. Steering motor 10. Oil cooler
4. Hand hammer control valve 11. Return line distributor block
5. Hand hammer 12. Filter
6. Backhoe control valve 13. Oil cooler by-pass valve
7. Loader control valve
 Copyright ©

34 SECTION 35 - HYDRAULIC SYSTEM

OIL FLOW OPERATION

All loader/backhoe circuits in neutral

Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load sensing pressure
compensator.
A load sense gallery connects the compensators in
each control valve section.
When all control valves are in neutral the spools
prevent the flow of oil in each circuit and pressure in
the load sense line can bleed to tank through the 1
litre/min (0.30 gals/min) load sense return to tank
orifice in the backhoe control valve inlet cover.
Because there is no load sense pressure being
applied to the rear face of the flow balancer valve,
the valve will move against the spring and off its seat
when pump pressure reaches 15 bar. Pump flow is
now diverted back to tank and the balancer valve
maintains a standby pressure of 15 bar while the
circuits are in neutral.

1
2

5
7
6
F29287

Flow balancer valve operation - All spools in neutral

Pump standby pressure 15 bar
Return to tank
1. Load sense bleed orifice 1 l/min 5. Pump flow balancer (unload) valve
2. Load sense limiter (system relief valve) 6. Pump flow IN
3. Return to tank 7. To backhoe control valves
4. Load sense line
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 35

1 2 3

4 4 4

F29288

Load sensing flow sharing - All spools in neutral

Pump pressure
Trapped oil
Return to tank
1. Load non-return check valve
2. Load sense line
3. Pressure compensating valve
4. Spool

36 SECTION 35 - HYDRAULIC SYSTEM
One hydraulic circuit operating
When a single hydraulic circuit is operated the spool
in the control valve section is moved allowing oil to
flow past the lands of the spool and apply pressure
to the metering element of the pressure
compensating valve.
The metering element moves upwards to allow oil to
flow to the load check valve and at the same time
uncovers the drilling in the spool portion of the
pressure compensator valve enabling operating
pressure to be sensed in the load sense gallery.
As pressure increases to open the load check valve,
load sense pressure is applied to the spring side of
the flow balancer valve in the backhoe control valve
end cover. A higher pressure is now required to
1
7
6
Flow balancer valve operation - Hydraulic circuits operating
Pump pressure
Load sense pressure
Return to tank
1. Load sense bleed orifice 1 l/min
2. Load sense limiter (system relief valve)
3. Return to tank
4. Load sense line
Copyright ©
operate the flow balancer valve and pump pressure
increase accordingly.
When pump pressure overcomes the pressure
behind the load check valve, the valve opens
allowing oil to flow into the cylinder port.
Exhaust oil from the cylinder returns to tank through
the other port in the control valve section.
If the load sense pressure in a circuit reaches 195
bar, the load sense relief valve in the backhoe
control valve end cover will operate. Pump pressure
is now limited to 210 bar. This is the pressure
required to overcome the pressure of the flow
balancing valve spring (15 bar) plus the load
sensing pressure controlled at 195 bar.
2
5
F29289
5. Pump flow balancer (unload) valve
6. Pump flow IN
7. To backhoe control valves
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 37

1 2 3

4 4 4

F29290

Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to tank
1. Load non-return check valve 3. Pressure compensating valve
2. Load sense line 4. Spool

38 SECTION 35 - HYDRAULIC SYSTEM
Two or more hydraulic circuits operating
When two or more hydraulic circuits are operated
each circuit will operate at a different pressure.
If pump flow to a specific circuit is not controlled the
circuit requiring a lower operating pressure will work
faster than that requiring the higher pressure
because flow will take the path of least resistance.
To overcome this situation the pressure
compensating valve regulates the flow of oil to the
circuit operating at a lower load.
When two spools are operated simultaneously
pump pressure is applied to the metering element of
the pressure compensating valve in both valve
sections.
Both metering elements therefore move upwards
allowing oil to flow to the load check valves. At the
same time the aperture in the spool portion of the
pressure compensating valve is uncovered to allow
1
7
6
Load sense relief valve operating
Pump pressure at 210 bar
Load sense pressure at 195 bar
Return to tank
1. Load sense bleed orifice 1 l/min
2. Load sense limiter (system relief valve)
3. Return to tank
4. Load sense line
Copyright ©
operating pressure to be sensed in the load sensing
gallery.
Pump pressure will rise until it overcomes the
pressure behind the load check valve of the
heaviest loaded circuit and the pressure in the load
sense line is similarly at this high pressure.
The pressure required to operate the lower loaded
circuit is now too high and if not restricted will result
in the lower loaded circuit operating in preference to
and faster than the higher loaded circuit.
To compensate for this condition the load sense
pressure moves the metering element of the
pressure compensating valve in the lower loaded
circuit downwards and restricts the flow to the
circuit.
This balancing of flow and pressure according to
load ensures that both circuits operate
simultaneously and at a balanced flow rate.
2
5
F29291
5. Pump flow balancer (unload) valve
6. Pump flow IN
7. To backhoe control valves
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 39

1 2 3

4 4 4

F29292

Load sensing flow sharing - Two spools operating

st
1 spool operating pressure
2nd spool operating pressure
Trapped oil
Return to tank
1. Load non-return check valve 3. Pressure compensating valve
2. Load sense line 4. Spool
 Copyright ©

40 SECTION 35 - HYDRAULIC SYSTEM

LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve
assembly consists of two or three spool operated
sections:
Z Loader lifting
Z Bucket
Z Auxiliary 4x1 bucket
Usually the loader control valve has three valve
sections when is installed on the tractor the bucket 4
x 1.

A. 4x1 bucket section

B. Bucket section
C. Lifting section
1. End cover
2. Bucket 4x1 relief valve
3. Loader bucket relief valve (rod end) 240 bar
4. Hydraulic speed relief valve 165 bar
5. Hydraulic speed solenoid
6. Inlet section
7. Loader bucket relief valve (piston end) 165 bar
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 41

Removal
Z Lower the loader to the ground, with the bucket
firmly placed on the ground.
Z Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Z Unscrew and remove clamping screws to chassis.
Z Remove the control valve assembly from the
machine.
Z Installation is the reverse of the removal procedure.

Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm. Slide out the three tie rods (2).

Disassemble end cover (4), section control valves

(4), (5) and (6), and inlet section (7).
Check and possibly replace the O-rings (8) located
between the section control valves.
 Copyright ©

42 SECTION 35 - HYDRAULIC SYSTEM

BACKHOE CONTROL VALVE (WITH MECHANICAL CONTROL)

The backhoe control valve assembly is located on
the rear of the tractor. It consists of six or seven valve
sections together with an inlet and outlet end cover.
Valve sections are:
Z Stabilizer right
Z Stabilizer left
Z Lifting
Z Dipper
Z Slew
Z Bucket
Z Telescopic (optional)

K. Hydraulic diagram for centre pivot (4WS) 2. Inlet section

W. Hydraulic diagram for sideshift 3. Dipper circuit relief valve (piston end) - 240 bar
A. Right stabilizer section 4. Bucket circuit relief valve (piston end) - 220 bar
B. Left stabilizer section 5. Swing circuit relief valve (piston end) - 205 bar
C. Dipper section 6. Lifting circuit relief valve (piston end) - 315 bar
D. Bucket section 7. Pump flow balancer - 15 bar
E. Swing section 8. Load sensing return to tank
F. Lifting section 9. Swing circuit relief valve (rod end) - 205 bar
G. Telescopic dipper section 10. Boom circuit relief valve (rod end) - 240 bar
H. Sideshift clamps valve 11. Telescopic circuit relief valve (rod end) - 205 bar
1. End cover 12. Load sensing relief valve - 210 bar
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 43

Removal
Z Position the tractor on a hard level surface.
Z Lower the loader to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z Tag and identify the position of all hoses.
Z Disconnect and plug all the hoses.
Z Disconnect the levers of the manual control.
Z Unscrew and remove clamping screws to chassis.
Z Remove the control valve assembly from the
tractor.
Z Installation is removal procedure in reverse.

Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm.
Slide out the three tie rods (2).

Disassemble end cover (3), section control valve (4),

(5), (6), (7), (8), (9) and (10), inlet section (11).
Check and possibly replace the O-rings (12) located
between the section control valve.
 Copyright ©

44 SECTION 35 - HYDRAULIC SYSTEM

Disassembly the inlet section.

Remove the pump flow balancer valve (13), load
sensing relief valve (14) and check valve (15) from
the inlet section (11).

Disassembly the outlet section.

(Sideshift version)

Unscrew the knob (16).

Remove the solenoid (17) and the 2 way valve (18).
Disassembly the shuttle valve (19).
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 45

Disassembly of control valve sections (with

mechanical control)
There are indicated all possible solutions relevant to
backhoe control sections with mechanical control.

1. Secondary relief valve 6. Spool with mechanical detent system (loader

2. Pressure compensator boom element)
3. Check valves 7. Spool with electrical detent system (loader
4. Plug bucket element)
5. Spool with spring return system
 Copyright ©

46 SECTION 35 - HYDRAULIC SYSTEM

Disassembly and reassembly mechanical control spool

Disassembly
Z Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Z Remove the mounting screws (D) and the cover
(E).
Z Remove the spool (F) from the valve section.
Z Remove the lip seal (L).

Z Use a spool clamp (G) and a vice to secure the

spool.
Z Heat the spool to 200 °C in an oven or with a heat
gun.
Z Remove the adapter (H), the retainers (I), the
spring (J), the plate (K) and the lip seal (L).
Z Remove the tongue (M) if necessary.

Reassembly
Z Reassemble parts in reverse order after greasing
the spring.
Z Position the metal part of the lip seal (L) on the
outside of the spool.
Z The lip seal must be fitted on the end of the spool
so that it is not damaged by the spool grooves (N)
and its tightness is not damaged.
Z Slide the lip seal perpendicularly onto the spool.
Z Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm.
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SECTION 35 - HYDRAULIC SYSTEM 47

Precautions to be taken for replacing the spool lip

seal.
Z Place the spool in the working section.
Z Slide the lip seal perpendicularly onto the spool,
positioning the metal part of the lip seal on the
outside of the spool.

SWARNING
The lip seal must be fitted on the end of the spool so
that it is not damaged by the spool grooves (N) and
its tightness is not damaged.

Mechanical detent system spool

Disassembly
Z Remove the tongue and the cover sides.
Z Use a spool clamp (G) and a vice to secure the
spool.
Z Using a metal rod (minimum length = 80 mm,
diameter 6) push the central ball (H) while
extracting the detent bush (I).
Z Mark the orientation of the detent bush for the
reassembly.
Z Remove the balls (J) and the spring (K) from the
adapter (M).

Reassembly
Z Introduce the spring (K) into the adapter (M).
Z Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Z Position the central ball (H) against the spring (K).
Z Slip the detent bush (I) onto a metal rod.
Z Using the metal rod, press the central ball (H) into
the adapter (M), then slide the detent bush (I) onto
the adapter, making sure that the 3 balls are still in
place.

NOTE: make sure that the orientation of the detent

bush is respected.
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48 SECTION 35 - HYDRAULIC SYSTEM

3.2 CONTROL VALVES “REXROTH” (PILOT MODELS)

The backhoe loader with hydraulic control (pilot

models) differs basically from the backhoe loader
with mechanical models for the reason that the
controls driving the backhoe loader and stabilizers
are hydraulic instead of being mechanic. By means
of the control levers located in the cab a control valve
is driven, that on its turn drives hydraulically the
backhoe control valve, monitoring the backhoe
loader and the stabilizers.
The backhoe loader with hydraulic control is
equipped with two control valves:
Z Loader control valve: mounted on the right hand
side of the backhoe loader and provides oil flow to
the loader boom and front bucket.
Z Backhoe control valve: located at the rear of the
chassis and provides oil flow to the backhoe,
stabilizers and rear bucket.
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SECTION 35 - HYDRAULIC SYSTEM 49

Hydraulic circuit oil Suction oil

Steering circuit oil Return to tank
Load sensing oil Control circuit oil

1. Oil tank 9. Backhoe hammer

2. Pump 10. Oil cooler
3. Steering motor 11. Return line distributor block
4. Hand hammer control valve 12. Filter
5. Hand hammer 13. Oil cooler by-pass valve
6. Backhoe control valve 14. Solenoid valve for piloting backhoe control valve
7. Loader control valve 15. Joystick
8. Backhoe hammer control valve 16. Accumulator
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50 SECTION 35 - HYDRAULIC SYSTEM

LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve
assembly consists of two or three spool operated
sections:
Z Loader lifting
Z Bucket
Z 4x1 bucket
Usually the loader control valve has three valve
sections when is installed on the tractor the 4x1
bucket.

A. 4x1 bucket section

B. Bucket section
C. Lifting section
1. End cover
2. Bucket 4x1 relief valve
3. Loader bucket relief valve (rod end) 240 bar
4. Hydraulic speed relief valve 165 bar
5. Hydraulic speed solenoid
6. Inlet section
7. Loader bucket relief valve (piston end) 165 bar
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SECTION 35 - HYDRAULIC SYSTEM 51

Removal
Lower the loader to the ground, with the bucket firmly
placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the machine.
Installation is the reverse of the removal procedure.

Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 ± 2 Nm. Slide out the three tie rods (2).

Disassemble end cover (4), section control valve (4),

(5) and (6), and inlet section (7).
Check and possibly replace the O-rings (8) located
between the section control valve.
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52 SECTION 35 - HYDRAULIC SYSTEM

BACKHOE CONTROL VALVE (WITH HYDRAULIC CONTROL)

The backhoe control valve assembly is located at the
rear of the tractor. It consists of six or seven valve
sections together with an inlet and outlet end cover.
Valve sections are:
Z Stabilizer right
Z Stabilizer left
Z Lifting
Z Dipper
Z Slew
Z Bucket
Z Telescopic (optional)

K. Hydraulic diagram for centre pivot (4WS) 8. Load sensing return to tank
W. Sideshift 9. Swing circuit relief valve (rod end) - 205 bar
A. Right stabilizer section 10. Lifting circuit relief valve (rod end) - 240 bar
B. Left stabilizer section 11. Telescopic circuit relief valve (rod end) - 205 bar
C. Dipper section 12. Load sensing relief valve - 210 bar
D. Bucket section
E. Swing section
F. Lifting section
G. Telescopic dipper section
H. Sideshift clamps
1. End cover
2. Inlet section
3. Dipper circuit relief valve (piston end) - 240 bar
4. Bucket circuit relief valve (piston end) - 220 bar
5. Swing circuit relief valve (piston end) - 205 bar
6. Lifting circuit relief valve (piston end) - 315 bar
7. Pump flow balancer valve - 15 bar
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SECTION 35 - HYDRAULIC SYSTEM 53

Removal
Position the tractor on a hard level surface.
Lower the loader to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Stop the engine and eliminate any residual pressure
in the backhoe and loader circuits by moving the
loader and backhoe control levers through all
operating positions.
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses and
hydraulic tubes.
Disconnect and plug all the hoses and all the
hydraulic tubes.
Unscrew and remove clamping screws to chassis.
Remove the control valve assembly from the tractor.
Installation is removal procedure in reverse.

Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 ± 2 Nm.
Slide out the three tie rods (2).

Disassemble end cover (3), sections control valves

(4), (5), (6), (7), (8), (9) and (10), inlet section (11).
Check and possibly replace the O-rings (12) located
between the sections.
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54 SECTION 35 - HYDRAULIC SYSTEM

Disassembly the inlet section.

Remove the pump flow balancer valve (13), load
sensing relief valve (14) and check valve (15) from
the inlet section (11).

Disassembly the outlet section.

(Sideshift version)

Unscrew the knob (16).

Remove the solenoid (17) and the 2 way valve (18).

Disassembly the shuttle valve (19).

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SECTION 35 - HYDRAULIC SYSTEM 55

Disassembly of control valve sections (with

hydraulic control)
In this section are indicated all possible solutions
relevant to backhoe control valve sections with
hydraulic control.

1. Secondary relief valve 3. Non return check valve

2. Pressure compensator 4. Plug
2A. Pressure compensator with shock absorber 5. Spring return system with guide
2B. Fixed pressure compensator 6. Spool
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56 SECTION 35 - HYDRAULIC SYSTEM

Disassembly and reassembly hydraulic control spool

Disassembly
Z Remove the screws (A), and the plate (B).
Z Extract the spring guides (C) and the springs (D).
Z Discard the seals (E).
Z Remove the spool (F) from the valve section.

Reassembly
Z Grease and install the spool (F) in the valve
section.
Z Install the springs (D) in the caps (B).
Z Install the spring guides (C) in the springs (D).
Z Install new seals (E).
Z Install the cap assemblies on the valve section,
install and tighten the screws (A) to a torque of 9 to
11 Nm.

Electrical detent system spool

Solenoid replacement (with spool pulled out)

Z Remove the 2 mounting screws (A) and the detent
system.
Z Unscrew the rear housing (B).
Z Remove the circlip (C), the spring and the coil.
Z Install a new solenoid (D).
Z Reassemble parts in reverse order.
Z Tightening torque:
screws (A) - 9 to 11 Nm
rear housing (B) - 1.8 to 2.2 Nm

Solenoid replacement (with spool pushed in)

Z Remove the solenoid (A).
Z Install a new solenoid.
Z Tightening torque - 18 to 22 Nm.
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SECTION 35 - HYDRAULIC SYSTEM 57

SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH HYDRAULIC CONTROL)

Solenoid valve is located under the cab floor and is

installed directly in the lower part of the chassis that
supports the operating levers. The solenoid valve is
installed with the pilot models and has the task to
transform the electrical controls, received from the
operating levers, in hydraulic controls and to send
those to the backhoe control valve. The module (A)
is installed only on the machines versions with
telescopic dipper. If the machine is not equipped
with telescopic dipper, the solenoid valve installed is
of type (B); while if the telescopic dipper is installed
the solenoid valve can be of type (A) + (B).
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58 SECTION 35 - HYDRAULIC SYSTEM

If the loader backhoe is equipped with telescopic

dipper and with the auxiliary control section valve on
the backhoe control valve, the solenoid valve
consists of valve (B) and module (C).

Removal
Z Position the tractor on a hard level surface.
Z Lower the loader to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Stop the engine and eliminate any residual
pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating positions.
Z Disconnect the battery.
Z Clean the area around the solenoid valve.
Z Tag and identify the position of all hoses and
hydraulic tubes.
Z Disconnect and plug all the hoses and all the
hydraulic tubes.
Z Unscrew and remove clamping screws to chassis
supporting the operating levers.
Z Remove the solenoid from the tractor.
Z Installation is removal procedure in reverse.

Disassembly
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).

SECTION 35 - HYDRAULIC SYSTEM
Untighten and remove the three screws (3) and
disassemble valve (4).
Check and possibly replace the O-rings (5).
In case of necessity it is possible to disassemble the
various solenoid valves from the manifold blocks.
Untighten and remove screws (6).
Disassemble solenoid valves (7).
Check and possibly replace the O-rings (8).
Untighten and remove valve (9).
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59
Check and possibly replace the O-rings (10).
Remove check valve (11) and orifice (12).
Untighten and remove solenoid valves (13).
Check and possibly replace the O-rings (14).
Untighten and remove solenoid valves (15).
Check and possibly replace the O-rings (16).
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60 SECTION 35 - HYDRAULIC SYSTEM

ACCUMULATOR “PARKER”

Technical specifications
Capacity (gas) ...........................................................................................................................................2 litres
Capacity (oil) ........................................................................................................................................1.84 litres
Precharge............................................................................................................................................ 30 ± 1 bar

Maintenance
Z Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable
intervals afterwards based on this initial experience.
Z Carry out a visual examination of the accumulator periodically in order to detect any early signs of
deterioration such as corrosion, deformation etc.
Z Comply with the regulatory provisions concerning the monitoring of operational equipment.
Z Before removal, it is vital to ensure that there is no residual hydraulic pressure in the accumulator. Discharge
the gas side of the accumulator using a Parker UCA charging and gauging assembly before carrying out any
maintenance operations

Safety
Charging must be carried out by qualified personnel.
Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic
system and the fluid side discharged in order to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.

Danger of Explosion - Never Charge with Oxygen

The types of nitrogen permitted are: type S (99.8% pure); type R (99.99% pure); type U (99.993% pure).
If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating
pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle.
Parker recommends that the precharge should be checked during the first week following commissioning of
the system.
Thereafter, it should be checked every three months, or at intervals determined by the system builder.

The Effect of Temperature on Precharge Pressure

In order to compensate for the difference in pressure at ambient and operating temperatures, it is
recommended that the precharge pressure po should be adjusted to reflect the operating temperature of the
system, using the correction factor equations and relevant table.

Warning - Stabilization
The process of charging or discharging an accumulator with nitrogen causes a temperature change which is
transmitted to the surrounding air as the temperature of the accumulator stabilizes. To allow for the effects of
temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes before a final
reading of the precharge pressure is taken.
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SECTION 35 - HYDRAULIC SYSTEM 61

Checking and Adjusting Precharge Pressure

The precharge pressure of an ACP Series accumulator may be checked, and nitrogen filled or vented, using
the UCA Universal Charging & Gauging kit tool 380002714.
The kit assembly is screwed onto the accumulator’s gas valve, allowing the precharge pressure to be checked
or reduced. If the precharge pressure is to be increased, the UCA can be connected to the nitrogen source with
the hose supplied. The kit is supplied with two pressure gauges, reading 0-25 bar and 0-250 bar; where a
different pressure range is required, a commercially-available pressure gauge may be used.
UCA kit 380002714 see drawing

A. Inflation valve
B. Bleed valve

1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert)
5. Pressure gauge
6. Protective cap - gauge port
7. Collar - gas port
8. Knurled protective cap - filling port
9. Hose (G1/4 fitting, 60° cone) with O-ring
10. Valve

Z Remove the protective cover and cap (11) from the

accumulator, to gain access to the gas valve (12).
Z Select the appropriate pressure gauge (5) for the
pressure to be checked, remove the protective cap
(6) and attach the gauge to the UCA (1).
Z Make sure that the bleed valve (B) is fully closed
and that the inflation valve (A) is in the fully raised
position by turning the handwheel in an anti-
clockwise direction.
Z Assemble the short adapter and adapter insert (3
and 4), screw onto the gas valve (13) and hand
tighten.
Z Screw the UCA onto the adapter. Position the
assembly to permit easy reading of the gauge, then
hand tighten the collar (7).
Z Open the inflation valve (A) by screwing the
handwheel clockwise until the inflation pressure
registers on the gauge.

Readings and Results

One of three conditions will apply - the precharge pressure in the accumulator will be correct, or it will be too
high or too low.
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62 SECTION 35 - HYDRAULIC SYSTEM

Nitrogen Pressure po is Correct

Z Screw the handwheel (A) anti-clockwise to close the accumulator gas valve.
Z Slacken the bleed valve (B) to release pressure in the UCA.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.

Nitrogen Pressure po is Too High

Z Slacken the bleed valve (B) to vent nitrogen from the accumulator until, after stabilization, the desired
pressure po is registered. Nitrogen vents into the air.
Z Tighten the bleed valve (B) once the desired filling pressure is reached.
Z Screw the handwheel (A) anti-clockwise to close the accumulator gas valve.
Z Slacken the bleed valve (B) to release pressure in the UCA.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.

Nitrogen Pressure po is Too Low

Z Close the inflation valve (A) by screwing the handwheel anti-clockwise.
Z Remove the cap (8).
Z Connect the end of the hose (9) to the valve (10).
Z Connect the other end of the hose to the nitrogen source.
Z Progressively open the valve on the nitrogen source.
Z Screw the handwheel (A) clockwise to admit the pressurized gas, taking particular care if the accumulator has
a small capacity.
Z When pressure po is reached, close the valve on the nitrogen source. To allow for the effects of temperature
transfer, the accumulator should be allowed to stand for a minimum of 15 minutes to allow the temperature to
stabilize before a final reading of the precharge pressure is taken.
Z Screw the handwheel (A) anti-clockwise to close the accumulator gas valve.
Z Slacken the bleed valve (B) to release pressure in the UCA.
Z Remove the hose carefully, to release internal pressure.
Z Refit the cap (8) on the valve (10).
Z Unscrew the UCA from the adapter(s).
Z Unscrew the adapters from the accumulator gas valve. After removing the UCA and adapter(s), make sure
that the accumulator gas valve (13) is sealing effectively. Refit the gas valve dust cap (12) and replace the
protective cover (11).
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SECTION 35 - HYDRAULIC SYSTEM 63

RELIEF VALVES
The relief valves may be operated with anti-
cavitation feature (1) or direct acting (2) and protect
individual circuits from excessive pressure.

The backhoes, having this kind of control valves

installed, are equipped with different relief valves.
Some of them are installed on the loader control
valve:
1. 4x1 bucket relief valve
2. Loader bucket relief valve (rod end) 240 bar
3. Hydraulic speed relief valve 165 bar
4. Loader bucket relief valve (piston end) 165 bar

Some of them are installed on the backhoe control

valve:
1. Dipper relief valve (piston end) - 240 bar
2. Bucket relief valve (piston end) - 220 bar
3. Swing relief valve (piston end) - 205 bar
4. Lifting relief valve (piston end) - 315 bar
5. Swing relief valve (rod end) - 205 bar
6. Lifting relief valve (rod end) - 240 bar
7. Telescopic relief valve (rod end) - 205 bar
8. Load sensing relief valve - 210 bar
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64 SECTION 35 - HYDRAULIC SYSTEM

Circuit relief valves operating

Relief valve inoperative

When the system is not subject to overload 1 2 3
conditions pressure in the system is insufficient to
overcome pilot valve spring pressure and move the
valve of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston 7 6 5 4 F29539

6. Control valve (cylinder) exhaust gallery Exhaust oil

7. Cylinder supply gallery High pressure oil

Pilot valve operation

When the cylinder is subjected to shock forces the 1 2 3
pressure increase in the cylinder supply gallery
overcomes pilot valve spring pressure lifting the pilot
valve off its seat.
System pressure on the rear face of the poppet
valve escapes to tank between the sleeve poppet
and valve body causing a pressure differential
between the front and rear face of the poppet valve.
The higher pressure in the cylinder supply gallery
unseats the poppet valve and moves the piston to
seat against the pilot valve.
1. Sleeve 7 6 5 4 F29540

2. Poppet valve Exhaust oil

3. Pilot valve High pressure oil
4. Pilot valve body Reduced pressure oil
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery

Pilot and poppet valve operation

The excessive system pressure in the cylinder 1 2 3
supply gallery now flows past the poppet valve to the
cylinder exhaust gallery and back to tank.

NOTE: during this operation the sleeve poppet is

held in the fully seated position by pressure oil.

1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston 7 6 5 4 F29541

6. Control valve (cylinder) exhaust gallery

High pressure oil
7. Cylinder supply gallery
Exhaust oil
Reduced pressure oil
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SECTION 35 - HYDRAULIC SYSTEM 65

Anti-cavitation operation
Circuit relief valves with an anti-cavitation feature
are fitted in circuits where rapid extension of the
cylinder could create a void condition and permit the
transfer of oil from the high pressure side of a
cylinder to the lower pressure (void) end of the
cylinder.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is
automatically replenished by the anti-cavitation
device in the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control valve
exhaust gallery acts on the outer face of the sleeve
poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.

2
1

5 4 F29542

High pressure oil

Anti-cavitation oil supply to cylinder
Relief valve exhaust oil
1. Anti-cavitation circuit relief valve 4. Control valve exhaust gallery
2. Cylinder rod 5. Spool
3. Circuit relief valve
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66 SECTION 35 - HYDRAULIC SYSTEM

Pilot operated with anti-cavitation feature circuit

relief valve subjected to overload and fully relieving 1 2 3
high pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery

7 6 5 4 F29543

Anti-cavitation cylinder resupply oil

Exhaust oil

Direct acting circuit relief valve operation

High pressure circuit oil is sensed in the cylinder 1 2 3 A
supply gallery and acts on the face of the relief valve
poppet.
When pressure in the circuit exceeds relief valve
setting the oil pressure lifts the poppet allowing
excess pressure in the overloaded cylinder to
escape to the exhaust gallery.

6 5 2 F29544

A. Direct acting circuit relief valve

Valve not subjected to overload conditions 1 2 3 B
B. Direct acting circuit relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil

6 5 2 F29545

Exhaust oil
High pressure circuit oil
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SECTION 35 - HYDRAULIC SYSTEM 67

Overhaul

IMPORTANT: before removing relief valves from

the machine lower the loader and backhoe to the
ground, switch engine off and relieve all pressure in
circuits by moving the backhoe, loader, and
telescopic dipper controls through all operating
positions. The circuit relief valves if suspected of
contamination may be disassembled and inspected
for wear but must be reset to the correct pressure.

The relief valves contain no serviceable components

with the exception of the external O-rings and
square section seals.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating
surface.

Pilot operated relief valve

1. Body 9. O-ring
2. Poppet 10. Locknut
3. Spring 11. O-ring
4. Spring 12. Adjuster
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Fitting 15. Piston
8. Cap 16. Poppet valve
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68 SECTION 35 - HYDRAULIC SYSTEM

Direct acting relief valve

1. Body 6. Cap
2. Poppet 7. O-ring
3. Spring 8. Locknut
4. Spring 9. O-ring
5. Shim 10. Adjuster screw

Loader bucket relief valve

1. Relief valve assembly

2. Spring 7. Guide
3. Locknut 8. Poppet
4. Valve body 9. Poppet sleeve
5. Adjuster 10. Valve body inner
6. Spring 11. Spring seat
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SECTION 35 - HYDRAULIC SYSTEM 69

Circuit relief valve adjustment

After overhaul the circuit relief valves must be tested
and adjusted using a suitable hand pump (1), 275
bar pressure gauge and V. L. Churchill test kit (2).

The hand pump must be attached to inlet port I and

the drain hose to the outlet port T of test block using
suitable 1/2 inch BSP (British Standard Pipe)
adaptors.
The pressure gauge may be connected to either the
hand pump as shown or to the 3/8 UNF threaded
port G in the test block.
Remove plug and insert valve to be tested into the
appropriate port in the test block as follows:
A. Stabilizer and backhoe relief valves
B. Loader bucket relief valves
C. Unload valve

NOTE: a special removable insert which, is part of

the test block, is installed in the bottom of the port
used for testing the loader valve. If difficulty is
experienced in screwing the loader valve into the
test block, check that the insert is fully seated and
correctly installed. When correctly installed the O-
ring (3) on the face of the insert should be visible.

Operate hand pump and record maximum pressure

reading on gauge. Compare pressure values with
previous specifications.

IMPORTANT: before removing valve from test block

release pressure in circuit using the vent valve on
the hand pump.
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70 SECTION 35 - HYDRAULIC SYSTEM

To adjust all relief valves with the exception of the

loader bucket relief valve remove the valve cap,
loosen locknut and turn adjuster to obtain correct
pressure.

NOTE: relief valves must not be set outside off the

specified range.

Loader bucket relief valve adjustment

NOTE: if the loader bucket circuit relief valve

requires adjustment, the special adjusting tool
supplied with the test kit is required as described
below.

Hold relief valve in vice and using wrench supplied

with tool, unscrew the internal valve assembly from
the valve body.
Screw the internal valve assembly (2) into the body
of the adjusting tool (1).

Install valve into test block and operate hand pump

until valve is pressurized to 170 bar.
Using the special spanner supplied, loosen the
locknut on the end of the valve and adjust pressure
setting using Allen wrench.
Operate hand pump and recheck pressure.
When pressure setting is correct tighten locknut and
release pressure in circuit using the vent valve on
the hand pump.
Remove valve and using 3/8 inch 16 UNC screw
remove insert, then reassemble valve and install into
test block.
Operate hand pump and recheck pressure.

If pressure is now lower than that recorded with the

insert installed it is an indication that the anti-
cavitation feature of the valve is leaking and the
valve requires overhaul or replacement.

NOTE: the insert isolates the anti-cavitation feature

of the valve. When reassembling the insert into the
test block ensure it is installed correctly. When
correctly installed the O-ring (3) on the face of the
insert should be visible.
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SECTION 35 - HYDRAULIC SYSTEM 71

4. HYDRAULIC SWING SYSTEM

4.1 DESCRIPTION AND OPERATION

The hydraulic swing system has two versions:

Z it can shift laterally with the backhoe attachment
because installed directly on the sideshift carriage
performing the shifting. This is possible only on the
loaders backhoes with sideshift version.
Z it is fixed because it is installed directly on the
chassis. This is possible only on loader backhoes
with centre pivot version.
The backhoe boom and digging elements can be
moved in an arc about the main chassis of 180
degrees.
This movement is obtained by the use of two
hydraulic cylinders (1) coupled between the main
chassis and swing post.
The cylinders act directly on the swing post, without
the use of any connecting links or bell cranks.
Each cylinder is free to rotate, around two pivots (3),
while the stem comes out or retracts inside of the
cylinder body (2).
As each cylinder extends or retracts and the swing
post rotates, the cylinders turn in a horizontal plate,
pivoting on the headstocks within the carriage.
Each cylinder is double acting and as hydraulic oil is
fed to a cylinder to turn the swing post, one cylinder
pushes and the other cylinder pulls to perform the
swing cycle.
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72 SECTION 35 - HYDRAULIC SYSTEM

4.2 HYDRAULIC OIL FLOW

Hydraulic feed to the swing cylinders is controlled by If the swing control valve is suddenly returned to
the swing section of the backhoe control valve which neutral mid-way through a full power swing the
contains pilot operated relief valves with anti supply and exhaust ports in the main control valve
cavitation feature to protect the circuit and cylinders are totally blocked.
should an overload condition occur. The momentum of the swinging backhoe assembly
The diagram illustrates operation of the swing circuit if not controlled will make the machine extremely
when retracting the right hand cylinder (4) and unstable.
extending the left hand cylinder (5) in order to swing To prevent this from occurring the circuit relief
the backhoe to the right. valves operate and dumps oil to exhaust until the
When swinging the backhoe to the left the oil flows excess pressure is relieved. When the relief valve
are reversed and exactly the same principle of operates the cylinder rod will move and a void will be
operation applies. created in the low pressure side of the cylinder. The
Oil flow for a right hand swing is as follows: anti-cavitation feature in the relief valves prevent the
When the swing control is operated the control valve void from occurring by transferring exhaust oil from
directs oil flow to the rod end of the right hand the excess pressure side of the circuit to the low
cylinder. pressure side.
The flow of oil at pump pressure lifts the one way
restrictor (2) of its seat allowing the flow to continue
unrestricted to the inlet port of the piston end of the
left hand cylinder.
System pressure increases causing the right hand
cylinder to retract and the left hand cylinder to
extend.
As the cylinders move, displaced oil on the piston
side of the left hand cylinder flows towards the one
way restrictor (7) in the inlet port on the rod end of
the right hand cylinder.
The oil flow moves the restrictor to the restrict
position which limits the flow of oil and creates a
back pressure (1st stage restricted return oil) in the
right hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve assembly (1) is
designed such that during operation oil can flow
freely through the port directing oil flow to the swing
cylinders but restricts the flow returning oil back to
tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted
return oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side
of the cylinder and be restricted on the exhaust side
a smooth controlled swing of the backhoe at
optimum speed is achieved.
When the swing system reaches the last 20-25° of
travel the sliding restrictor in the end of the piston
rod touches the outlet port in the cylinder barrel.
This further restricts the flow of oil exhausted from
the cylinder and as the piston moves towards the
end of its stroke the sliding restrictor is gently
pushed down the centre of the cylinder rod allowing
a progressive and controlled halt to the swing cycle.
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SECTION 35 - HYDRAULIC SYSTEM 73

7 2

6 3

5 4

F29480

Pump pressure oil

1st stage restricted return oil
2nd stage restricted return oil
Return to tank oil

1. Control valve swing section

2. One way restrictor
3. Cushioning rod
4. Right hand cylinder
5. Left hand cylinder
6. Cushioning rod
7. One way restrictor
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74 SECTION 35 - HYDRAULIC SYSTEM

4.3 PRECISION SWING CONTROL

Each of this assy consists of a valve (2) fitted on a

bracket (3) that is on its turn installed on rear axle (4)
and of some hydraulic pipings (6) connecting the
valves with the swing cylinders (7) and the backhoe
control valve (5).

OPERATION

Backhoe swing circuit without precision swing

control
When the backhoe is being swung from side to side
and the control valve spool is returned to the neutral
position, the pressure generated by the inertia of the
backhoe structure will cause the cylinders to
continue to stroke as oil is forced over the circuit
relief valve. The high pressure induced by this inertia
in the return circuit and corresponding low pressure
in the supply side of the circuit, provides the force
difference which causes the backhoe to move in the
opposite direction (rebound). This condition can
occur multiple times and give the appearance of
loose or worn pins.

Backhoe swing circuit with precision swing

control
The anti-rebound valve monitors conditions in the
swing circuit as it speeds up, slows down, moves at
a steady speed or is stopped. When stopped,
speeding up or moving at a steady speed, the
system is inactive. Neither swing speed, power or
internal leakage is affected.
When the swinging boom is brought to a stop the
anti-rebound valve is designed to meter oil from one
side of the swing cylinder circuit to the other. The
system is activated only when the control valve spool
is in the neutral position and the cylinder return oil
passes over the port relief. At that point, the return
side of the circuit becomes the high-pressure side
with the oil passing through the 100 psi check (A).
This 100 psi pressure differential across the check
shifts a throttling spool (B) that allows a restricted
“cross over” flow between the two swing cylinders.
This restricted flow allows the swing cylinders to de-
accelerate to a smooth stop. When the swing has
stopped the pressure differential decreases and the
throttling spool closes.
If the oil temperature in the swing circuit is not above
approximately 80 degrees F, a thermal
compensating feature prevents the spool from
overcoming the spring force holding it closed. Below
this actuation temperature the system performs as if
the feature were not installed.
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SECTION 35 - HYDRAULIC SYSTEM 75

PRECISION SWING CIRCUIT

1. Port to cylinder 4. Port from valve

2. Screen 5. Shuttle valve
3. Throttling spool (B) 6. Restrictor (A)

PRECISION SWING VALVE COMPONENTS

1. Port to cylinder 7. Thermal actuator

2. Check valve 0.3 bar 8. Thermal spring
3. Screen 9. Thermal compensating spool
4. Orifice 10. Return spring
5. Orifice plug 11. Port from valve
6. Check valve 6.9 bar 12. Shuttle check valve

76 SECTION 35 - HYDRAULIC SYSTEM
PRECISION SWING VALVE FAULT FINDING
Measurement of swing drift
On horizontal ground, tilt unit approximately 10° with
stabilizers. Extend the boom, dipper, and bucket so
they are horizontal. Warm unit up to approximately
49 °C (valve will be warm to the touch).
Centre boom, lower to the ground, and make a mark
with the bucket (or line up an object with a bucket
tooth). Raise bucket to approximately 6”.
Turn unit off and wait 5 minutes. Lower boom (no
swing!) to the ground.
Measure the difference between mark (or reference
object) and bucket tooth.
Delay check leaks
Symptom:
The backhoe linkage would likely swing slowly to
one side during roading / loading of the backhoe.
Verification method:
Switch swing port relief valves. If the drifting
switches to the opposite side, the problem is with
the relief valve.
Perform swing drift test measurement. If the check
is leaking, the measured distance will increase
significantly.
Performing the swing drift test with a cross-over
orifice plugged would eliminate the cross-over spool
as a cause of the leakage.
Shuttle valve leaks
Symptom:
The backhoe linkage would likely swing slowly to
one or both sides during roading / loading of the
backhoe.
Verification method:
See “Delay Check Leaks” above.
Cross-over spool leaks
Symptom:
The backhoe linkage would likely swing slowly to
both sides during roading / loading of the backhoe.
The swing may drift slowly after almost stopping
when the unit is tilted.
Verification method:
Perform the swing drift test and then repeat the test
with a cross-over orifice plugged.
This would determine if the cross-over spool is the
cause of the leakage.
By-pass orifice contaminated
Symptom:
The backhoe linkage would likely drift slowly to one
side after the swinging motion is stopped and the
unit is tilted slightly.
Copyright ©
Verification method:
Repeat the motion, so that the drift occurs again,
and then add tilt to the unit. Repeat the motion
several times to verify that drift is not reproducible at
higher angles.
Delay orifice or delay screen contaminated
Symptom:
The backhoe boom takes longer than normal to stop
from a swinging motion in both directions.
Verification method:
Perform the swing drift test with a cross-over orifice
plugged. If the symptom stops, this would indicate
that the delay orifice is contaminated.
Thermal by-pass fails
Symptom:
The backhoe boom takes longer than normal to stop
from a swinging motion in both directions when
starting in cold weather or the system may not
actuate after oil is warmed up.
Verification:
In cold weather, remove the cross-over spool
assembly, and with snap ring pliers, remove all
internal components. Reinstall the crossover spool
in the valve and verify that the backhoe boom stops
quickly and with some oscillations.
If the system is not activating after the oil is warmed
up, remove the cross-over spool assembly. Push
the back of the thermal actuator and verify that it
easily strokes approximately ¼”. With snap ring
pliers, remove all internal components. Visually
inspect the thermal actuator for evidence of
damage.
6.9 or 0.3 bar main flow check fails
Symptom:
Anti-rebound valve works well in one direction, but
doesn’t work in the other direction.
Verification method:
Remove the swing anti-rebound valve. Switch the
check valves from one side to the other side. Make
sure that the black (6.9 bar) check valves are
inserted closest to the mounting surface, and that
the direction of good performance is noted before
the swap.
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SECTION 35 - HYDRAULIC SYSTEM 77

5. HYDRAULIC CYLINDERS

1. Loader cylinder
2. Loader bucket cylinder
3. Bucket cylinder 4x1
4. Backhoe boom cylinder
5. Backhoe dig cylinder
6. Backhoe bucket cylinder
7. Cylinder telescopic
8. Cylinder swing backhoe
9. Stabilizer cylinder (centre pivot models)
10. Stabilizer cylinder (sideshift models)
11. Sideshift carriage cylinder (sideshift models)
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78 SECTION 35 - HYDRAULIC SYSTEM

5.1 LOADER CYLINDER

4WS

1. Stroke
2. Completely retracted

2WS

1. Stroke
2. Completely retracted
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SECTION 35 - HYDRAULIC SYSTEM 79

REMOVE LOADER CYLINDER

Park machine on a flat surface. Raise the loader
sufficiently to allow the loader cylinder pin to be
removed.
Remove the loader bucket and support the arm
using a suitable stand or hoist.

SWARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal
injury may occur.

Relieve the residual pressure in the system by F30317

moving the loader control lever through all operating

positions.
Stop the engine.
Support the cylinder using sling and suitable hoist.
Disconnect the hydraulic hoses. Cap or plug all
exposed openings.

F30318

Disconnect the hydraulic hoses.

Remove the snap ring (1) and the spacer (2).
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80 SECTION 35 - HYDRAULIC SYSTEM

Remove the ring (3) and the pin (4).

Use a hammer to slide out the rod pin (5).

Remove the loader cylinder.

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SECTION 35 - HYDRAULIC SYSTEM 81

DISASSEMBLY LOADER CYLINDER

1. Rod 9. Back-up ring

2. Bushing 10. O-ring
3. Wiper seal 11. Piston
4. Seal 12. Piston seal
5. Seal 13. Piston ring guide
6. Guide bush 14. Screw
7. Cylinder head 15. Tube
8. Gasket 16. Bushing

The disassembly procedure below starts on the

premise that the hydraulic lines have already been
removed.

SWARNING
Cylinder weight: 36 kg.

Lift and securely place the cylinder on a workbench.

Be sure that the cylinder is placed horizontally. Drain
hydraulic oil from cylinder.
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82 SECTION 35 - HYDRAULIC SYSTEM

Fully extend the rod (1).

Use the wrench 380000725 to loose the cylinder
head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Remove the cylinder head (7) from the tube (15) by

using with a plastic hammer. Remove the rod (1) and
buffer head (4).

IMPORTANT: be sure to pull out cylinder rod (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (14). Slide out the

rod (1) and the piston assy (11) and the cylinder
head assy (7).

Only if required:
Z Remove from the cylinder head (7), the wiper ring
(3), the seal (4), the seal (5), the bearing sleeve (6)
and the back-up ring (9) with O-ring (10).
Z Remove from the piston (11) the seal (12) and the
ring guide (13).
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SECTION 35 - HYDRAULIC SYSTEM 83

5.2 LOADER BUCKET CYLINDER

4WS

1. Stroke
2. Completely retracted

2WS

1. Stroke
2. Completely retracted
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84 SECTION 35 - HYDRAULIC SYSTEM

REMOVE LOADER BUCKET CYLINDER

Park machine on a flat surface and position the
bucket firmly on the ground.
Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
Support the cylinder using sling and suitable hoist.
Disconnect hydraulic hoses.

Support the link rods.

Remove the snap ring (1) with the spacer (2).
Remove the pin (3) using an hammer.

Remove the snap ring (4) with the spacer (5).

Remove the pin (6) using an hammer.

Remove the loader bucket cylinder.

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SECTION 35 - HYDRAULIC SYSTEM 85

DISASSEMBLY LOADER BUCKET CYLINDER

1. Bushing 9. O-ring
2. Rod 10. Piston
3. Wiper ring 11. Piston seal
4. Seal 12. Piston ring guide
5. Seal 13. Screw
6. Cylinder head 14. Tube
7. Snap ring 15. Bushing
8. Back-up ring

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 32.5 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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86 SECTION 35 - HYDRAULIC SYSTEM

Support the rod (2) and use the wrench 380000722

to loose the cylinder head (6).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Remove the stop ring (7).

Pull out the cylinder head (6) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (2) and the cylinder head (6).

IMPORTANT: be sure to pull the cylinder rod (2)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (13).

Slide out rod (2) and the piston assy (10) and the
cylinder head assy (6).

Only in case of need:

Z remove the cylinder head (6), the wiper ring (3), the
seal (4), the seal (5), the back up ring (8) with the
O-ring (9);
Z remove from the piston (10) the piston seal (11)
and the ring guide (12).
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SECTION 35 - HYDRAULIC SYSTEM 87

5.3 4X1 BUCKET CYLINDER

1. Cylinder rod pin 5. Stud

2. Dowel 6. Nut
3. Bucket 7. Cylinder bottom pin
4. Cylinder

CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket firmly on the ground.
Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
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88 SECTION 35 - HYDRAULIC SYSTEM

Disconnect hydraulic hoses.

Unscrew and remove the clamping screws of cover

(C). Remove the cover (C).

Remove the pin (2). Slide out the pin (1) with an
hammer.

Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.

Remove the 4x1 bucket cylinder.

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SECTION 35 - HYDRAULIC SYSTEM 89

DISASSEMBLY CYLINDER

1. Tube 7. Cylinder head

2. Piston 8. Gasket
3. Pin 9. Wiper seal
4. O-ring 10. Rod
5. Piston guide 11. Bushing
6. O-ring
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90 SECTION 35 - HYDRAULIC SYSTEM

5.4 BACKHOE BOOM CYLINDER

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Stop the engine and move the backhoe control

levers through all operating positions to relieve all
residual pressures in the system.

Position a sling or other suitable lifting equipment

around the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 91

Untighten and remove the screw (1). Slide out the

pin (2) with an hammer.

NOTE: the tube end of the dig cylinder and the rod
end of the boom cylinder use a common attaching
pin (2).

If the boom cylinder has to be disassembled, slide

out the pin only partially (2), then remove the
cylinder rod and finally reinsert the pin.
If necessary use hydraulic power to very slowly
retract the cylinder so that the rod comes clear of the
attaching point.

Disconnect hydraulic hoses. Remove the stop ring

(3) and slide out the head pin (4).

NOTE: accurate positioning of the cylinder prior to

hose disconnection will aid pin removal.

Remove the backhoe boom cylinder.

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92 SECTION 35 - HYDRAULIC SYSTEM

BACKHOE BOOM CYLINDER DISASSEMBLY

1. Wiper ring 11. Piston gasket

2. Bushing 12. Piston
3. Rod 13. Piston gasket
4. Wiper ring 14. Washer
5. O-ring 15. Screw
6. Guide bush 16. Cylinder tube
7. Cylinder head 17. Bushing
8. Back-up ring 18. Wiper ring
9. O-ring 19. Screw
10. Piston ring guide

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 80.5 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 93

Fully extend the cylinder rod (3).

Remove the safety screw (19). Use the wrench
380000724 to loose the cylinder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (7) from the cylinder tube
(16) by tapping with a plastic hammer. Remove
cylinder rod (3) and the cylinder head (7).

IMPORTANT: be sure to pull cylinder stem (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (15) with the

relative washer (14). Slide out the rod (3) and the
piston assy (12) and the cylinder head assy (7).

Only in case of need:

Z remove from the cylinder head (7), the wiper ring
(4),O-ring (5), the guide bush (6), and the back-up
ring (8) with O-ring (9);
Z remove from the piston (12), the piston ring guide
(10) and the piston gaskets (11) and (13).
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94 SECTION 35 - HYDRAULIC SYSTEM

5.5 BACKHOE DIPPER CYLINDER

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Stop the engine and move the backhoe control

levers through all operating positions to relieve all
residual pressures in the system.

Position a sling or other suitable lifting equipment

around the cylinder.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 95

Untighten and remove the nut (1) and the dowel (2).
Hammer to slide out the rod pin (3).
If necessary use hydraulic power to very slowly
retract the cylinder so that the rod comes clear of the
attaching point.

Disconnecting hydraulic hoses. Untighten and

remove the screw (4). Slide out the pin (5) with an
hammer.
The tube end of the dig cylinder and rod end of the
boom cylinder use a common attaching pin (5).
Therefore before shifting the dig cylinder, support
the boom cylinder with a rope or an hoist.

Remove the backhoe dig cylinder.

 Copyright ©

96 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY DIPPER BACKHOE CYLINDER

1. Wiper ring 10. Piston ring guide

2. Bushing 11. Piston gasket
3. Rod 12. Piston
4. Wiper ring 13. Washer
5. O-ring 14. Screw
6. Guide bush 15. Cylinder tube
7. Cylinder head 16. Bushing
8. Back-up ring 17. Wiper ring
9. O-ring 18. Screw

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 64 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 97

Fully extend the cylinder rod (3).

Remove the safety screw (19). Use the wrench
380000724 to loose the cylinder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (7) from the cylinder tube
(15) by tapping with a plastic hammer. Remove
cylinder rod stem (3) and the cylinder head (7).

IMPORTANT: be sure to pull cylinder stem (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (15) with the

washer (13). Slide out the rod (3) and the piston assy
(12) and the cylinder head assy (7).

Only if required:
Z remove from the cylinder head (7), the wiper ring
(4), O-ring (5), the guide bush (6), and the back-up
ring (8) with O-ring (9);
Z remove from the piston (12) the piston ring guides
(10) the and piston gasket (11).
;;
;;
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98 SECTION 35 - HYDRAULIC SYSTEM

5.6 BACKHOE BUCKET CYLINDER

(1) Stroke
(2) Completely retracted

BACKHOE BUCKET CYLINDER REMOVAL

Park the machine on a flat surface. Lay the backhoe
bucket firmly on the ground.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Stop the engine and move the backhoe control

levers through all operating positions to relieve all
residual pressures in the system.

Position a sling or other suitable lifting equipment

around the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 99

Remove the stop ring (1) with the shim (2). Slide out
the pin (3) by means of hammer and pay attention to
levers.
If necessary use hydraulic power to very slowly
retract the cylinder.

Disconnect hydraulic hoses. Unscrew and remove

the screw (4) and slide out the pin (5) by means of
hammer.

Remove the backhoe bucket cylinder.

 Copyright ©

100 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY BACKHOE BUCKET CYLINDER

1. Wiper ring 10. Piston gasket

2. Bushing 11. Piston ring guide
3. Rod 12. Piston
4. Wiper ring 13. Screw
5. O-ring 14. Cylinder tube
6. Guide bush 15. Bushing
7. Cylinder head 16. Wiper ring
8. Back-up ring 17. Screw
9. O-ring

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 64 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 101

Fully extend the cylinder rod (3).

Remove the safety screw (19). Use the wrench
380000725 to loose the cylinder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (3) and the cylinder head (7).

IMPORTANT: be sure to pull cylinder stem (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (13). Slide out the

rod (3) and the piston assy (12) and the cylinder
head assy (7).

Only if required:
Z remove from the cylinder head (7), the wiper seal
(4), O-ring (5), the bearing sleeve (6), and the back-
up ring (8) with the O-ring (9);
Z remove from the piston (12) piston the ring guide
(11) and the piston gasket (10).
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102 SECTION 35 - HYDRAULIC SYSTEM

5.7 SHORT AND LONG TELESCOPIC CYLINDER

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Stop the engine and move the backhoe control

levers through all operating positions to relieve all
residual pressures in the system.

Remove the snap ring (1). Hammer to slide out the

pin (2) from the other side.
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SECTION 35 - HYDRAULIC SYSTEM 103

Disconnect hydraulic connections (3), at dipper

cylinder and support cylinder using suitable hoist.
Remove the snap ring (5). Hammer to slide out the
pin (4) from the other side.

Remove the telescopic cylinder.

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104 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY TELESCOPIC CYLINDER

1. Rod 8. Back-up ring

2. Wiper ring 9. O-ring
3. Seal 10. Piston gasket
4. Seal 11. Piston ring guide
5. Guide bush 12. Piston
6. Screw 13. Screw
7. Cylinder head 14. Cylinder tube

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 45 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 105

Fully extend the cylinder rod (1).

Unscrew and remove the safety screw (6). Use the
wrench 380000721 to loose cylinder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove
cylinder rod (1) and the cylinder head (7).

IMPORTANT: be sure to pull the cylinder rod (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (13). Slide out the

rod (1) and the piston assy (12) and the cylinder
head assy (7).

Only if required:
Z remove from the cylinder head (7), the wiper ring
(2), the seal (3), the seal (4), the guide bush (5), the
O-ring (9) with the back-up ring (8);
Z remove from the piston (12) the piston ring guide
(11) and the piston gasket (10).
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106 SECTION 35 - HYDRAULIC SYSTEM

5.8 STABILIZER CYLINDER (CENTRE PIVOT - 4WS)

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Make sure that the backhoe loader is locked in the
transfer position or parked in a safety work position.
Lower the stabilizers to the ground.

Support the cylinder safely with suitable belt and

hoist.
Remove the snap ring (1) and the shim (2).
Hammer out the pin (3) and by means of hydraulic
power, retract the cylinder very slowly.
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SECTION 35 - HYDRAULIC SYSTEM 107

With engine stopped, release any residual pressure

by moving the control levers of stabilizers.
Disconnect all hydraulic pipings. Remove the snap
ring (4) and the shim (5). Hammer to slide out the pin
(6).

Remove the stabilizer cylinder.

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108 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY STABILIZER CYLINDER (CENTRE PIVOT)

1. Rod 8. Back-up ring

2. Wiper ring 9. O-ring
3. Seal 10. Piston gasket
4. Seal 11. Piston ring guide
5. Guide bush 12. Piston
6. Screw 13. Screw
7. Cylinder head 14. Cylinder tube

The disassembly procedure that follows takes into

consideration the hydraulic piping already
disassembled.

SWARNING
Cylinder weight: 43.5 kg

Lift and place the cylinder on a workbench and

secure it. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
 Copyright ©

SECTION 35 - HYDRAULIC SYSTEM 109

Fully extend the cylinder rod (1).

Remove the safety screw (6). Use the wrench
380000726 to loose cylinder head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (7) from the cylinder tube
(14) by tapping with a plastic hammer. Remove the
cylinder rod (1) and the cylinder head (7).

IMPORTANT: be sure to pull cylinder stem (1)

straight so as not to damage the sliding surfaces.

Untighten and remove the screw (13). Slide out the

rod (1) and the piston assy (12) and the cylinder
head assy (7).

Only in case of need:

Z remove from the cylinder head (7), the wiper ring
(2), the seal (3), the seal (4), the guide bush (5), the
O-ring (9) with the back-up ring (8);
Z remove from the piston (12) the piston ring guide
(11) and the piston gasket (10).
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110 SECTION 35 - HYDRAULIC SYSTEM

5.9 STABILIZER CYLINDER (SIDESHIFT)

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Park the machine on a flat surface and position the
bucket on the ground.

Lower the stabilizers to the ground.

Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
Remove the snap ring (1) with the spacer (2) and
pull out the pin (3) from the opposite side so as to
release the rod of the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 111

Disconnect the hydraulic tubes at the top of the

stabilizer leg.
Remove the cylinder pin locking screw (4).
Fit a 1/2 inch- 13x1.50 threaded eye screw and
shackle in the threaded hole on the top of the
cylinder. Ensure that the threaded portion of the eye
screw does not screw into the waisted section of the
pin (5).
Remove the pin (5).

Lift the stabilizer cylinder from the casing.

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112 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY STABILIZER CYLINDER (SIDESHIFT)

1. Rod 8. O-ring
2. Wiper ring 9. Piston
3. Seal 10. Piston ring guide
4. Seal 11. Piston gasket
5. Cylinder head 12. Screw
6. Snap ring 13. Cylinder tube
7. Back-up ring

The disassembly procedure that follows takes into

consideration the hydraulic pipings already
disassembled.

SWARNING
Cylinder weight: 33.7 kg

Lift and place the cylinder on a workbench and

secure it to a vice. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 113

Fully extend the cylinder rod (1).

Remove the wire retaining (6). Use the wrench
380000721 to loose cylinder head (5).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.

Pull out the cylinder head (5) from the cylinder tube
(13) by tapping with a plastic hammer. Remove the
cylinder rod (1) and the cylinder head (5).

IMPORTANT: be sure to pull cylinder rod (1) straight

so as not to damage the sliding surfaces.

Untighten and remove the screw (12). Slide out the

rod (1) and the piston assy (9) and the cylinder head
assy (5).

Only if required:
Z remove from the cylinder head (5), the wiper ring
(2), the seal (3), the seal (4), and the back-up ring
(7) with O-ring (8);
Z remove from the piston (9) the piston ring guide
(10) and the piston gasket (11).
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114 SECTION 35 - HYDRAULIC SYSTEM

5.10 SWING CYLINDER

(1) Stroke
(2) Completely retracted

CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe
elements for cylinder removal using a suitable stand.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Stop the engine and move the backhoe control

levers through all operating positions to relieve all
residual pressures in the system.

Untighten and remove the nuts (1). Slide out the

screw (2) from the opposite side. Now the pin (3) can
come out and release the rod cylinder. If necessary
hammer to help the pin (3) to come out.
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SECTION 35 - HYDRAULIC SYSTEM 115

Disconnect the feed and return hose to the cylinders

and cap all exposed openings.
Untighten and remove the nuts (4) and the screws
(5) (from both sides).
Now it is possible to remove the support (6).

Carefully lift and remove the swing cylinder from the

swing bracket.
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116 SECTION 35 - HYDRAULIC SYSTEM

DISASSEMBLY SWING CYLINDER

1. Bushing 10. Trunnion

2. Wiper ring 11. O-ring
3. Rod 12. Back-up ring
4. Wiper ring 13. Piston seal
5. Seal 14. Piston guide ring
6. Seal 15. Piston
7. Guide bush 16. Lock retaining piston
8. Bushing 17. Tube
9. Ring seal

The disassembly procedure that follows takes into

consideration the hydraulic pipings already
disassembled.

SWARNING
Cylinder weight: 31 kg

Lift and place the cylinder on a workbench and

secure it to a vice. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from cylinder.
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SECTION 35 - HYDRAULIC SYSTEM 117

Use the wrench 380000725 to loose cylinder head

(10).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Remove the rod assy with the trunnion and the
piston assy.

Unscrew and remove the piston lock (16). Slide out

rod (3) and piston assy (15) and the trunnion (10)
complete with gaskets.
Check the bushings (8) status.

Only in case of need:

Z remove from the trunnion (10), the wiper ring (4),
the rod seal (5), the buffer seal (6), the guide bush
(7) and the back-up ring (12) with O-ring (11).
Z remove from the piston (15) the piston seal (13)
and the ring piston guide (14).

REASSEMBLY AND INSTALLATION

Reassembly follows the disassembly procedure in
reverse whilst observing the following:
1. Tighten the piston lock retaining to a torque of
1400 - 1540 Nm.
2. Tighten swing cylinder plate retaining screws to
a torque of 607 Nm.
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118 SECTION 35 - HYDRAULIC SYSTEM

5.11 BACKHOE SIDESHIFT LOCKING CYLINDER (SIDESHIFT)

They are installed on the loader backhoe n. 4

sideshift locking cylinders. Their function is to lock
the carriage once the backhoe attachment is ready
in the digging position.
The cylinder consists of:
1. Piston
2. Plate
3. O-ring
4. Back-up ring

CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket on the ground.

Position the backhoe support in the centre of the

machine and lower the backhoe on the ground.
Support the backhoe elements using a suitable
stand and hoist capable of carrying 1500 kg.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

F30321

Lower the stabilizers to the ground.

Relieve the residual pressure in the system by
moving the loader control lever through all operating
positions.
Position a trolley jack beneath the backhoe support.
Disconnect all hydraulic pipes that link the backhoe
attachment to the machine.

F30322
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SECTION 35 - HYDRAULIC SYSTEM 119

Remove the 6 clamps screws on the bottom of the

support followed by the 6 screws (5) on top of the
carrriage (torque 1030 Nm). 5

F30323

Use the trolley jack to raise the backhoe support

from the frame and carefully move the machine
forward sufficiently to allow access to the sideshift
carriage cylinder. Do not allow the hydraulic hoses
to be stretched when moving the machine forward.

SWARNING
Before moving machine forward check that backhoe
is still fully supported by the hoist and remains
stable.

F30324

Remove the plate (2).

Using and slide hammer remove the piston (1).
If necessary, replace O-ring (3) and back-up ring (4).
1

3 4
F30325
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120 SECTION 35 - HYDRAULIC SYSTEM

5.12 SPECIAL TOOLS

P/N CNH DESCRIPTION APPLICATION

380000721 Wrench Telescopic dipper cylinder head
Stabilizer cylinder head (sideshift)
380000722 Wrench Loader bucket cylinder head
380000724 Wrench Backhoe boom cylinder head
Backhoe dipper cylinder head
380000725 Wrench Backhoe bucket cylinder head
Swing cylinder head
Loader cylinder head
380000726 Wrench Stabilizer cylinder head (centre pivot)
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SECTION 35 - HYDRAULIC SYSTEM 121

6. HYDRAULIC CONTROL LEVERS

6.1 TECHNICAL SPECIFICATIONS

Weight 5.1 ÷ 5.3 kg

Spool stroke 7.55 mm

SPECIAL TORQUE SETTINGS

Maximum permissible on the hydraulic control lever 80 Nm

Control block retaining screw 30 Nm

Control block universal joint 50 Nm

Control block nut 40 Nm

Lower body screw 50 Nm


122 SECTION 35 - HYDRAULIC SYSTEM
6.2 DESCRIPTION AND OPERATION
1. CONTROL CANCELLATION SWITCH: with the
switch in “ON” (alight) position all the backhoe
attachment controls are functional.
2. LEFT-HAND HYDRAULIC CONTROL LEVER:
the left-hand lever controls attachment swing
and the boom or the dipper (depending on the
control pattern adopted).
3. RIGHT-HAND HYDRAULIC CONTROL
LEVER: the right-hand lever controls the bucket
and the boom or the dipper (depending on the
control pattern adopted).
4. CONTROL PATTERN CHANGE SWITCH: this
switch is used for changing the standard control
pattern to the ISO pattern.
5. WARNING HORN BUTTON: press the tip of the
left-hand hydraulic control lever to sound the
audible warning device (momentary action).
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6. TELESCOPIC DIPPER CONTROLS:
(proportional controls) (if fitted).
Press the right-hand button to extend the dipper.
Press the left-hand button to retract the dipper.
7. AUXILIARY BI-DIRECTIONAL CONTROL (if
fitted): press the left hand button and hold down
to get the oil flow out the right side of the boom.
Press the left hand button and hold down to get
the oil flow out the left side of the boom.
8. STABILIZER CONTROL: the right-hand control
is for the right-hand stabilizer and the left-hand
control in for left-hand stabilizer.
9. SUPPORT TILT ADJUSTMENT HYDRAULIC
CONTROL LEVER
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SECTION 35 - HYDRAULIC SYSTEM 123

RIGHT HAND HYDRAULIC CONTROL LEVER

1. Valve 10. Half handle

2. Plate 11. Cap
3. Screw 12. Switches
4. Nut 13. Grommet
5. Boot 14. Spacer
6. Connector 15. Clip
7. Wedge 16. Clip
8. Half handle 17. Plugs [if the switches (12) are not fitted]
9. Screw
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124 SECTION 35 - HYDRAULIC SYSTEM

LEFT HAND HYDRAULIC CONTROL LEVER

1. Valve 11. Cap

2. Plate 12. Switch push button (horn)
3. Screw 13. Grommet
4. Nut 14. Spacer
5. Boot 15. Clip
6. Connector 16. Clip
7. Wedge 17. Plugs [if the switches (18) are not fitted]
8. Half handle 18. Switch push buttons (aux bi-dir)
9. Screw 19. Connector
10. Half handle 20. Wedge
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SECTION 35 - HYDRAULIC SYSTEM 125

6.3 DISASSEMBLY AND ASSEMBLY

Disassembly
Release pressure in the hydraulic circuits using the
following procedure: turn key switch “ON”, but do not
start the engine. Turn pilot control cancellation
switch to the “ON” position. Move both joysticks in all
directions. Turn key switch “OFF”. Disconnect the
negative battery cable(s).
Z Mark the position of the lever parts (see the
exploded view on previous pages).
Z Remove knob (P) and support (S).
Z Remove bracket (O) with relevant screws (with left
hydraulic control lever).

Z Remove decal (D), mounting plate (D1) and detach

connectors (Q) (with left hydraulic control lever).
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126 SECTION 35 - HYDRAULIC SYSTEM

Z Pull out both switches (I) and detach relevant

connectors (Q1) (with right hydraulic control lever).

Z Remove knob (P1) in the rear section of hydraulic

control lever.

Z Remove screws (V) and plate (N).

Z Lift rubber boot (RL) for left hydraulic control lever

and (RR) for right hydraulic control lever.
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SECTION 35 - HYDRAULIC SYSTEM 127

Z Tag all hydraulic hoses before disconnecting them.

Disconnect all hoses (H).
Z Disconnect all connectors (Q2).

Z Remove screws (V1) and take out hydraulic control

lever from the column.

Z Remove the screws (9). Separate the half handles

(8) and (10). Remove the cap (11).
Unscrew the nut (4) and remove the screw (3).
Remove the spacers (14). Remove the boots (5).
Remove the plate (2).

Reassembly
To reassemble the hydraulic control levers, proceed
in the reverse order to that of removal.
Follow the marks made during disassembly, and
tighten the nut (4) to a torque of 36 to 44 Nm.
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128 SECTION 35 - HYDRAULIC SYSTEM

6.4 HYDRAULIC CONTROL LEVER VALVE

P. Supply
T. Tank return

Right valve (dipper/bucket) Left valve (backhoe/swing)

1. Retracting the dipper 1. Lifting
2. Opening the backhoe bucket 2. Right swinging
3. Extending the dipper 3. Lowering
4. Closing the backhoe bucket 4. Left swinging
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SECTION 35 - HYDRAULIC SYSTEM 129

1. Universal joint cam 12. Cup

2. Plate 13. Lock ring
3. Shim 14. Spring
4. Upper body 15. Spool
5. Rod guide 16. Shims
6. Seal 17. Screw
7. Seal 18. Seal
8. Rod 19. Lower body
9. Bearing 20. Seal
10. Spring 21. Seal
11. Shim

130 SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC CONTROL LEVER VALVE OVERHAUL
Disassembly
1. Mark the direction of installation of all
disassembled parts.
2. Remove the U/J cam (1) using a key.
3. Remove the plate (2).
4. Remove the shim (3) from the upper body (4).
5. Extract the rod guide (5) and replace the seals
(6) and (7).
6. Drift the rod (8) out.
7. Remove the bearing (9), the spring (10) and the
shims (11).
8. Extract the spool assembly.
9. Hold the cup (12) and remove the lock ring (13).
10. Remove the spring (14) and the spool (15).
11. Remove and note the thickness of the shims
(16).
12. Proceed in the same manner for the other rods.
13. Secure the upper body (4) in a vice.
14. Loosen and remove the screw (17) using a key
and replace the seal (18).
Copyright ©
15. Separate the upper (4) and lower (19) bodies
and replace the seals (20) and (21).
Reassembly
1. To reassemble, proceed in the reverse order to
that of removal.
2. In the case of reassembly without changing the
U/J cam (1), put the same value of shims (3) as
those in place.
3. After changing the U/J cam (1) adjust the
pressure of the cam on the rods.
4. Install a 2 mm shim (3), check that the recessing
of the push-rods is less than 0.2 mm, modify the
shimming to more or less if required.
5. Install new seals (6), (7), (18), (20) and (21).
6. Lubricate the moving parts.
7. Apply brake thread fluid on the threads of the U/
J cam (1) and the screw (17).
8. Tighten the U/J cam (1) to 50 Nm and the screw
(17) to 50 Nm.
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SECTION 35 - HYDRAULIC SYSTEM 131

7. FAULT FINDING AND FLOW TESTING

7.1 PRELIMINARY CHECKS

If fault finding, pressure and flow testing is carried out

in a systematic manner and the results analyzed, the
malfunction can be readily and accurately identified.
If short cuts, assumptions and guesses are made,
unnecessary strip-down or component replacement
could result. Follow the step-by-step procedures
outlined below.
As a first step in the fault finding procedure, several
preliminary checks should be made. These checks
are important in that once performed, they need no
longer be considered as a possible cause of the
immediate or reported malfunction.
Z Check that the hydraulic oil is at the correct level
and of the correct specification.
Z Check the loader, backhoe or any additional
accessory such as hydraulic bucket, hammers etc.,
for correct assembly or installation and additionally
for signs of external damage that might cause gross
misalignment of structural members.
Z Check in more detail for other mechanical damage
such as kinked, twisted, worn or decayed hoses,
damaged cylinders and bent elements.
Z Do not forget to check underneath the unit for
damaged steel tubes, particularly if the unit has
been known to have operated in arduous
conditions, been grounded, or bogged down.
Z Ensure optimum operating temperature of the
hydraulic oil is achieved.
Z Perform the system pressure and rear pump relief
valve pressure tests.
The preceding preliminary checks assume that the
engine performance is not in question. Having
performed these checks and failed to locate the
cause of the malfunction, the following procedures
should be adopted:
Z If possible, operate the backhoe and make notes of
the operating characteristics. Cycle each control
lever to operate each of the cylinders to the fully
extended and retracted positions.
Z Compare the operating characteristics in the
preceding stage with the malfunctions listed
hereunder.

132 SECTION 35 - HYDRAULIC SYSTEM
7.2 FAULT FINDING
GENERAL
PROBLEM CAUSE
All circuits fail to operate Pump drive inoperative
Low oil level
Restricted pump suction line
Slow operation or loss of power in Pump worn
all circuits
Restricted pump suction line
Load sense pressure relief valve
incorrectly adjusted
Hydraulic speed solenoid valve
inoperative
LOADER
PROBLEM CAUSE
Lift fails to operate, is slow or has Valve spool leakage
loss of power
Piston seals leaking or cylinder
barrel damaged
Bucket fails to operate, is slow or Circuit relief valves stuck open,
has loss of power set too low or seat leaking
Valve spool leakage
Piston seals leaking or cylinder
barrel damage
Cylinder leak down (spools in Piston barrel damaged
neutral)
Internal valve leakage
Hesitation in loader lift or bucket Load check valve between
cylinders when control initially control valve sections damaged
moved
Copyright ©
ACTION
Investigate and repair as necessary.
Check and add oil.
Inspect suction line and tank, repair
as necessary.
Perform pump performance test and
replace/reseal as necessary.
Inspect suction line and tank, repair
as necessary.
Pressure test system.
Pressure test system.
ACTION
Examine lift section of loader control
valve assembly for wear or scoring.
Examine/reseal piston and gland.
Bucket circuit relief valve test.
Examine bucket section of loader
control valve assembly for wear or
scoring.
Examine/reseal piston and gland.
Examine/reseal piston and gland.
Examine appropriate valve section
of loader control valve assembly for
wear or scoring.
Disassemble and inspect.
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SECTION 35 - HYDRAULIC SYSTEM 133

BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. The backhoe chart
should only be referred to if the supply circuit is performing normally, thereby confirming that the pump and
hydraulic supply circuits are functioning to specification. See also “Fault finding hydraulic pump”.

PROBLEM CAUSE ACTION

Lift fails to operate, is slow, has Lift circuit relief valve stuck open, Pressure test lift circuit relief valve.
loss of power or is not holding set too low or seat is leaking

Valve spool leakage Examine lift section of backhoe

control valve assembly for wear and
scoring.

Piston seals leaking or cylinder Examine/reseal piston and gland.

barrel damaged
Diggind fails to operate, is slow, Digging circuit relief valve (piston Pressure test digging circuit relief
has loss of power end) stuck open, set too low or valve.
seat is leaking

Valve spool leakage Examine digging section of backhoe

control valve assembly for wear and
scoring.

Piston seals leaking or cylinder Examine/reseal piston and gland.

barrel damaged
Bucket fails to operate, is slow, Bucket circuit relief valve (rod Pressure test bucket circuit relief
has loss of power end) stuck open, set too low, or valve.
seat is leaking

Valve spool leakage Examine bucket section of backhoe

control valve assembly for wear and
scoring.

Piston seals leaking or cylinder Examine/reseal piston and gland.

barrel damaged
Telescopic dipper fails to operate, Telescopic dipper relief valve Pressure test telescopic dipper
is slow, has loss of power (piston end) stuck open, set too circuit relief valve.
low, or seat is leaking

Valve spool leakage Examine telescopic dipper section of

backhoe control valve assembly for
wear and scoring.

Piston seals leaking or cylinder Examine/reseal piston and gland.

barrel damaged
Stabilizer leg leaks down Stabilizer lock valve leaking Examine/overhaul stabilizer lock
valve.

Piston seals leaking or cylinder Examine/reseal piston and gland.

barrel damaged

134 SECTION 35 - HYDRAULIC SYSTEM
SWING
PROBLEM
Right or left direction swing fails
to operate, is slow, or has loss of
power
Swing fails to slow (cushion
arrest) at end of travel
Swing continues to move when
control lever returned to neutral
(one direction only)
Cylinders leak down (spools in
neutral)
Any one circuit lowers
momentarily when signalled to
raise
CAUSE
Swing circuit relief valves not
seating, set too low or seat is
leaking
Valve spool leakage
Piston seals leaking or cylinder
barrel damaged
Integral sliding restrictor
damaged
Piston seals leaking or cylinder
barrel damage
Circuit relief valve (return side)
stuck open, set too low or seat
leaking
Valve spool leakage
Internal valve leakage
Piston seals leaking or cylinder
barrel damaged
Load check valve between
control valve sections damaged
Copyright ©
ACTION
Swing circuit relief valve test.
Examine swing section of backhoe
control valve assembly for wear or
scoring.
Examine/reseal piston and gland.
Disassemble and inspect.
Examine/reseal piston and gland.
Swing circuit relief valve test.
Examine swing section of backhoe
control valve assembly for wear or
scoring.
Examine appropriate valve section
of backhoe control valve assembly
for wear or scoring.
Examine/reseal piston and gland.
Disassemble and inspect.

SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC PUMP
PROBLEM CAUSE
System noisy Worn or damaged pump gears or
pressure plates
Aeration: air entering the systems
at: suction tube, pump shaft,
fittings, or cylinder glands
Cavitation: restrictions in the
system at the suction line or at
the suction screen in the tank
Water in the system
System relief valve chatter
Tubing vibration
Cold hydraulic oil
Wrong type oil being used
Hydraulic oil exhausts from Tank overfilled
breather at the tank
Aeration: air entering the system
at: suction tube, pump shaft,
fittings, or cylinder glands
Cavitation: Restriction in the
system at the suction screen in
the tank
Oil heating Oil supply low
Contaminated oil
Setting of relief valve too high or
too low
Oil in system too light
Oil cooler fins blocked
Shaft seal oil leakage Worn shaft seal
Foaming oil Low oil level
Air drawn into suction line
Wrong oil grade
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135
ACTION
Hydraulic pump performance test.
Hydraulic pump performance test.
Visual and/or hydraulic pump
performance test.
Visual.
Check system relief valve, adjust/
overhaul as necessary.
Visual.
Check hydraulic oil operating
temperature.
Investigate/drain and refill.
Check hydraulic oil level.
Hydraulic pump performance test.
Visual and/or hydraulic pump
performance test.
Fill tank.
Drain tank and refill with clean oil.
Drain tank and refill with clean oil.
Test relief valves.
Drain tank and refill with correct
viscosity oil.
Clean oil cooler.
Replace shaft seal and inspect
pump.
Fill tank.
Check/tighten suction line.
Drain and refill with correct oil.
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136 SECTION 35 - HYDRAULIC SYSTEM

7.3 PRESSURE TESTING

Steering standby
Install 0 - 40 bar pressure gauge into the middle test
port (1) on left hand side of machine.
Set engine speed to 1000 rev/min.
Ensure no turning force is being applied to the
steering wheel and observe pressure on gauge.
The pressure gauge should read approximately 17
bar and is the steering standby pressure.
If pressure incorrect remove and examine flow
divider spool on end of pump.

Steering circuit relief valve

Install 0 - 200 bar pressure gauge into the middle
test port (1) on left hand side of machine.
Set engine speed to 2000 rev/min and fully turn and
hold steering on either full left or right hand turn and
observe pressure gauge. The gauge reading should
rise to 175 - 183 bar and is the steering circuit relief
valve setting.
If reading is not to specification stop engine, remove
blanking plug on pump flow divider and using
screwdriver turn relief valve adjusting screw to
increase or decrease setting.
Retest steering and when pressure correct peen end
of adjuster to prevent movement and reinstall
blanking plug.

System pressure relief valve

Install 0 - 300 bar pressure gauge into upper test
port (1).
Set engine speed to 2200 rev/min.
Raise loader until bucket is approximately 0.5
meters from the ground. This ensures that self
leveling device does restrict movement of bucket
during this test.
Hold the loader bucket control lever to the left
causing the bucket to roll back.
Observe the reading on the upper gauge which will
display the system pressure relief valve setting.
Pressure reading should be 210 bar.
If relief valve is away from specification adjust to
specification.
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SECTION 35 - HYDRAULIC SYSTEM 137

Loader bucket relief valve (piston end)
Set engine speed to 2200 rev/min.
Hold the loader bucket control lever to the right
causing the bucket to dump.
Observe the upper gauge which should read 160
bar minimum and is the operating pressure of the
loader bucket, piston end, relief valve. Values up to
190 bar are acceptable.
Adjust valve if not to specification.
To test rod end circuit relief valve hold lever to the
left and curl in the bucket. If pressure reading is 210
bar the system relief valve is operating and it is an
indication that relief valve which is set at 230 bar is
set correctly.
Telescopic dipper relief valve (piston end)
Set engine speed to 2200 rev/min.
Fully extend the telescopic dipper and continue to
depress the control pedal.
Observe the reading on the gauge.
Pressure recorded is the telescopic dipper relief
valve setting and should read 165-167 bar
minimum. Values up to 200 bar are acceptable.
Adjust valve if not to specification.
Dipper bucket and boom relief valves
These relief valves are set to a higher pressure than
the main system relief valve setting of 210 bar. To
test these circuit relief valves operate each service
until the corresponding relief valve operates.
If pressure reading in each incidence is 210 bar.
The system relief valve is operating and it is an
indication that relief valves are set correctly.
Dipper bucket circuit relief valve (rod end)
specification is 220 bar. Dipper boom circuit relief
valve setting (piston end) is 240 bar.
To accurately test the dipper bucket (rod end) and
boom (piston end) relief valves the main system
pressure can be temporarily increased to 240 bar.
Do Not increase pressure setting to higher than 240
bar and reset system relief valve to 210 bar on
completion of test.
Dipper boom circuit relief valve setting (rod end) is
315 bar and can not be checked using this system.
Replace this valve if considered faulty.

Swing system relief valves

Set engine speed to 2200 rev/min.
Hold dipper fully left until relief valve operates and
blow relief valve. Observe the upper gauge which
should read 205 bar minimum.
Repeat procedure with dipper held to the right.
Adjust valve if not to specification.
Observe the reading on the gauge in the lower test
port.
Pressure recorded is the telescopic dipper relief
valve setting and should read 165-167 bar
minimum. Values up to 200 bar are acceptable.
Adjust valve if not to specification.
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138 SECTION 35 - HYDRAULIC SYSTEM

FLOW TESTING

Pump performance test

The following pump performance test must be
performed after pressure testing the system and
rear pump relief valves and when the hydraulic oil is
at normal operating temperature of 75 °C.
Disconnect inlet and outlet hoses to backhoe control
valve and install 0 - 200 L/min flowmeter.
Open flowmeter valve.
Slowly turn flow control valve and increase pressure
to 175 bar. Measure pump flow which should be: 69
- 81 litres/min.

Analysis
If flow recorded in step 3 is less than 69 litres/min the
pump is worn and requires overhaul.

NOTE: if the machine has a history of poor service

intervals replace the hydraulic system filter and
clean pump intake filter in the tank.
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 39 - CHASSIS

1. DESCRIPTION AND OPERATION............................................................................................................... 3

2. REMOVAL AND INSTALLATION COMPONENTS ...................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS .............................................................................................. 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS....................................................................... 8
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS .......................................................................... 9
2.5 TIGHTENING TORQUES .................................................................................................................... 11
 Copyright ©

2 SECTION 39 - CHASSIS
 Copyright ©

SECTION 39 - CHASSIS 3

1. DESCRIPTION AND OPERATION

This section can be used as a quick reference for
general disassembly of the machine and its compo-
nents.

The chassis of the Backhoe Loader is manufactured

as a one piece unit on which the major assemblies
are attached or supported from.
The chassis are mainly of two kinds and differ from
one other according to the kind of backhoe attach-
ment that the backhoe loader should carry:
Z CENTRE PIVOT: means that the backhoe is con-
nected directly to the chassis and cannot shift later-
ally (only for 4WS).
Z SIDESHIFT: means that the backhoe is installed on
the side shift support and can shift laterally on the
chassis guides.
The chassis change according to the machine steer-
ing (2WS or 4WS) because of the different wheel
shape; or because the machine can be equipped ei-
ther with “straight” loader arm (2WS machines) or
with “bent” loader arm (4WS machines).
 Copyright ©

4 SECTION 39 - CHASSIS

4WS CENTRE PIVOT CHASSIS (BENT LOADER ARM)

2WS SIDESHIFT CHASSIS (STRAIGHT LOADER ARM)

4WS SIDESHIFT CHASSIS (BENT LOADER ARM)

 Copyright ©

SECTION 39 - CHASSIS 5

2. REMOVAL AND INSTALLATION COMPONENTS

2.1 COMPONENTS WITHIN THE CHASSIS

ENGINE
Supported by 2 rubber silent blocks and held in po- Remove:
sition by 2 support brackets. The brackets, which Air Cleaner bowl
are welded to the frame one either side of the en- Engine guard and panels
gine are positioned just ahead of the loader posts. Radiator’s and related hoses (Or pivot forward
where possible)
SWARNING Front support cowling (if required)
The engine and transmission bolted together act as
a one piece unit. If separated in the machine they Disconnect:
are not self supporting and will collapse causing in- Fuel pump throttle cable and electric shut off
jury or damage to the machine. Engine harness
Fuel tank connection and leak off return pipes
Hydraulic pump and related pipework (plug all ports
TORQUE CONVERTOR as required)
Transmission Lever
Fitted between the engine and the transmission can
Transmission harness connectors
only be removed when the engine/transmission as-
Engine supports (with engine supported by hoist)
sembly are separated.
Transmission supports
TRANSMISSION
Attached to the rear of the engine and supported in
rubber silent blocks in fixed brackets and held within
the frame just at the rear of the loader post.
To make repairs that require disassembly of the
transmission or engine it will be necessary to re-
move the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the ma-
chine it will be necessary to remove or disconnect
the following:

6 SECTION 39 - CHASSIS
2.2 COMPONENTS BELOW THE CHASSIS
FRONT AXLE
The front axle is attached to the underside of the
chassis by 6 through screws (2WS) or 4 through
screws (4WS).
To remove front axle from the machine:
Z Park the machine on a flat ground.
Z Stop the engine, remove the key and relieve resid-
ual pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating position.
Z Lower the stabilizers on the ground.
Z Lower the loader bucket on the ground.
Z Using the loader bucket raise the front of the ma-
chine, high enough to remove the front wheels.
Z Place stands under the chassis, supporting appro-
priately the machine.
Place under the axle the appropriate supporting/
removing tool.
Z Remove the nuts on the wheels and then remove
them.
Z Disconnect the steering cylinder hoses.
Z Remove the axle swivel pin attaching bolts (4WD).
Z Disconnect the spider coupling (4WD).
Z Remove the axle bolts.
Z Remove the front axle.
Copyright ©
REAR AXLE
The rear axle is attached to the frame at the rear of
the machine by 4 through bolts.
To remove rear axle from the machine:
Z Park the machine on a flat ground.
Stop the engine, remove the key and relieve resid-
ual pressure in the backhoe and loader circuits by
moving the loader and backhoe control levers
through all operating position.
Z Lower the stabilizers on the ground.
Z Lower the loader bucket on the ground.
Z Using the stabilizers, raise the rear of the machine,
high enough to remove the rear wheels.
Z Place stands under the chassis, supporting appro-
priately the machine.
Z Remove the nuts from the wheels and then remove
them.
Z Disconnect the steering cylinder hoses (4WS).
Z Disconnect the brake circuit hoses.
Z Disconnect the connector of harness of the differ-
ential lock (electrically controlled version).
Z Remove the precision swing assy if installed (see
Section 35).
Z Remove axle swivel pin attaching bolts.
Z Disconnect spider coupling.
Z Remove the axle bolts.
Z Remove the rear axle.
 Copyright ©

SECTION 39 - CHASSIS 7

COUNTERWEIGHT

Counterweight: is installed under the chassis in the

front section of the machine with two bolts.
The weight of the counterweight (1): 160 kg
 Copyright ©

8 SECTION 39 - CHASSIS

2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS

TANKS
Attached to the chassis below the cab are the tanks
for hydraulic oil (1) mounted to the right hand side of
the machine and the fuel tank (2) mounted to the left
hand side of the machine.
Both tanks when drained of their contents can be re-
moved from the machine by removal of the attach-
ing pipe work and supporting bolts.

IMPORTANT: ensure all ports and pipes are

plugged or blanked off to prevent dirt ingress.
 Copyright ©

SECTION 39 - CHASSIS 9

2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS

CAB

A. Front fixing 7. Fixing bolt

B. Rear fixing 8. Washer
S. Cab skirts 9. Cab floor
1. Main frame 10. Cab support (rear)
2. Anti-vibration 11. Support
3. Dampener 12. Boss
4. Washer 13. Cab support (front)
5. Washer
6. Nut
 Copyright ©

10 SECTION 39 - CHASSIS

The cab frame is a one piece unit mounted on top of

the chassis. The mains operations that have to be
done in order to remove the cab are:
Z Remove the cab skirts (S) all around the cab.
Z Disconnect the two electrical connectors from the
main harness and engine harness.
Z Remove the two front fixing bolts (7) between the
cab floor and the cab support (13) (detail A).
Z Remove the two rear fixing bolts (7) between the
cab floor and the rear supports (10) on the main
frame (1) (detail B).
Z Disconnect the two steering cylinder hoses (left
side).
Z Disconnect the pump - power steering valve hose.
Z Disconnect the power steering valve - oil tank
hose.
Z Disconnect the load sensing valve hose.
Z Disconnect the stabilizers cables (mechanical ver-
sion).
Z Disconnect the hand brake cable.
Z Disconnect the water - heater hoses (after water
discharge).
Z Disconnect the air conditioning hoses (after refrig-
erant drain).
Z Disconnect the transport lock cable (mechanical
version).
Z Disconnect the telescopic dipper control pedal
(mechanical version).
Z Remove the knobs and the boots of the various le-
vers (front and rear).
Z Lift the cab with the crane after its anchorage to lift-
ing hook.

IMPORTANT: when lifting the cab ensure the hy-

draulic brake tanks are not caught and damaged on
the loader support frame.
 Copyright ©

SECTION 39 - CHASSIS 11

2.5 TIGHTENING TORQUES

In the following table are the torques for the various assemblies that should be removed to affect repair.

IMPORTANT: always ensure prior to carrying out repairs on the machine that the vehicle parking brake is on
and the wheels are chocked.

ENGINE/TRANSMISSION
ù

COMPONENTS TORQUES
Engine/Transmission retaining bolts and nuts 95 Nm
Engine coolant tank retaining bolts 25 Nm
Engine/Transmission bolts 95 Nm
Air cleaner retaining bolts to frame 25 Nm
Coolant radiator bolts to frame 95 Nm
Radiator retaining bolts to frame 95 Nm
Front panel cowling to frame 214 Nm
Front bonnet to frame 170 Nm
Upper and front panel to frame 80 Nm
Front cardan joint to axle 38 Nm
Front cardan joint to transmission 38 Nm
Rear cardan joint to axle 38 Nm
Rear cardan joint to transmission (PS) 38 Nm
Rear cardan joint to transmission (PT) 70 Nm

FRONT/REAR AXLE

COMPONENTS TORQUES
Front axle retaining bolts to frame (2WS) 500 Nm
Front axle retaining bolts to frame (4WS) 500 Nm
Rear axle to frame retaining bolts (2WS) 800 Nm
Rear axle to frame retaining bolts (4WS) 900 Nm

HYDRAULIC SYSTEMS

COMPONENTS TORQUES
Power steering hoses to support frame 55 Nm
Backhoe control valve to frame bolts 90 Nm
Loader control pipes clamp to frame 25 Nm

TANK

COMPONENTS TORQUES
Oil tank holding bolts 85 Nm
Fuel tank holding bolts 85 Nm
 Copyright ©

12 SECTION 39 - CHASSIS

FRONT COUNTERWEIGHTS

COMPONENTS TORQUES
Weight 700 Nm

LOADER

COMPONENTS TORQUES
Loader control pipe bracket to frame 25 Nm

BACKHOE
COMPONENTS TORQUES
Backhoe to frame hose retaining clamps 52 Nm
Boom to swing bracket 190 Nm
Stabilizers upper pins retaining bolt 80 Nm

CAB
COMPONENTS TORQUES
Cab support 450 Nm
Front cab retaining bolts 210 Nm
Rear cab retaining bolts 180 Nm

WHEELS
COMPONENTS TORQUES
Front/rear wheels to axle (4WS) 700 Nm
Front wheel to axle (2WD) 330 Nm
Front wheel to axle (4WD) 330 Nm
Rear wheel to axle (2WS) 540 Nm
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 41 - STEERING SYSTEM

1. STEERING SYSTEM 2WS ........................................................................................................................... 4

2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. POWER STEERING ................................................................................................................................... 12
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 16
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING.................................................................................................................................. 33
 Copyright ©

2 SECTION 41 - STEERING SYSTEM

 Copyright ©

SECTION 41 - STEERING SYSTEM 3

The steering system shows these features:

Z double acting, type steering cylinder on both 2 and
4WD axles;
Z common hydraulic tank with the main hydraulic
system;
Z a tandem gear pump located on the rear of the
transmission; both pumps are driven by a shaft run-
ning directly off the flywheel.
Oil is drawn through the common inlet port into both
pumping elements.
The front pump flow is directed to the loader and
backhoe control valves and side shift clamping sys-
tem.
Rear pump flow passes through the flow divider
valve which maintains priority oil flow to the steer-
ing system with remaining flow directed for stabiliz-
ers, loader and backhoe elements.
The flow divider, located on the rear of the pump,
comprises a load sensing valve and steering sys-
tem pressure relief valve.
The valve ensures a priority oil flow to the steering
system while the steering is operated, with the re-
maining flow directed to the stabilizer, loader and
backhoe circuits;
Z load sensing power steering.
 Copyright ©

4 SECTION 41 - STEERING SYSTEM

1. STEERING SYSTEM 2WS

LAYOUT

1. Flow divider 6. By-pass valve

2. Power steering 7. Cooler
3. Oil tank 8. Front axle
4. Return manifold
5. Oil filter
 Copyright ©

SECTION 41 - STEERING SYSTEM 5

POWER STEERING - NEUTRAL

F29379

Pump pressure Trapped oil

Stand-by pressure Return to tank

When the steering wheel is held still, the leaf springs

return and hold the power steering spool in the neu-
tral position.
This ensures no more oil is supplied to the steering
cylinder. The spool also traps the oil in the steering
cylinder and allows oil in the sensing lines to return
to tank therefore allowing the priority flow divider to
move to the left.
 Copyright ©

6 SECTION 41 - STEERING SYSTEM

POWER STEERING - TURNING RIGHT

F29384

Pump pressure Trapped oil

Metered pressure Return to tank

When the steering wheel is turned, the movement of

the power steering spool forms a series of passag-
es. During right turn, oil flows through the spool
along a groove and into a passage in the housing
which leads to the metering unit. A gallery is also
lined up to allow pressure oil to flow down the sens-
ing line to the priority flow divider.

As the metering unit is turned by the drive shaft, it di-

rects a measured quantity of oil along another set of
passages in the spool then from these to the steer-
ing cylinder.

Return oil from the other side of the cylinder is di-

rected through the spool to a return passage in the
housing.
 Copyright ©

SECTION 41 - STEERING SYSTEM 7

2. STEERING SYSTEM 4WS

LAYOUT

1. Flow divider (hydraulic pump) 6. By-pass valve

2. Power steering 7. Cooler
3. Oil tank 8. Front axle
4. Return manifold 9. Steering control valve
5. Oil filter 10. Rear axle
 Copyright ©

8 SECTION 41 - STEERING SYSTEM

STEERING CONTROL VALVE

The steering control valve is located just above the
rear axle attached to the main chassis.
Remove the four pipes and then the 2 chassis fixing
bolts, then withdraw the valve for overhaul.
Draw a diagonal line across the complete valve
block this will assist in the correct reassembly later.

The valve consists of a central manifold block which

all input and output pipes are attached to. On each
side of this block is a solenoid valve. The solenoid
valves have two positions, both of these positions
are working positions and there is no neutral point.
Each spool is detented and therefore the solenoids
are only energized momentarily to move the spool.
On the end of each solenoid is an emergency hand
operating pin which moves the control spool without
energizing the solenoid. The switching of the steer-
ing valve is normally controlled by a microprocessor
located underneath the right hand side console.

1. Solenoid knob 6. Fixing screws

2. Solenoid 7. Plunger
3. Control spool 8. O-rings
4. Block 9. O-ring
5. Central block
 Copyright ©

SECTION 41 - STEERING SYSTEM 9

STEERING VALVE DIAGRAM

In the position shown both spools have been moved

by solenoids (2b) and (3b); the detents on the (a)
side of the solenoid hold the spool in this position
until another solenoid is pulsed.
 Copyright ©

10 SECTION 41 - STEERING SYSTEM

T3

P3
A3 B3

A2 B2
P2

T2

F29529

The spool in valve (3) was last moved by solenoid

(3b): oil flowing in from P3 flows through the internal
galleries of the spool and exits at port A3. From
here, oil enters valve (2), whose spool was last
moved by solenoid (2b). Oil flows through port P2
and exits through port T2, cutting off flow to the rear
steering cylinder. Now the oil returns in valve (3),
entering through port B3 and flowing out through
port T3. From here, oil enters the front steering cyl-
inder.
 Copyright ©

SECTION 41 - STEERING SYSTEM 11

The three modes of steering are as follows:

Front wheel only steering

Front and rear wheel steer

Front and rear wheel crab

The solenoids energized are shown in the table be-

low.
These are also the pins which need to be pressed
when changing steering mode manually in an emer-
gency.

X = Energized
O = Not Energized

3a 3b 2a 2b

2WS O X O X

2WS X O O X

4WS O X X O

CRAB X O X O
 Copyright ©

12 SECTION 41 - STEERING SYSTEM

3. POWER STEERING
The steering unit consists of a metering pump that
includes:
Z a gear wheel assembly with fixed stator (with inner
teeth) and a rotor (with outer teeth).
Z A 4 ways rotary distributor consisting of an outer
sleeve and an inner selection rotor.
The selection rotor is connected to the steering
wheel, through column, that can be of two types:
fixed or adjustable.
Z A cardan shaft, mechanically tied to gear wheel as-
sembly and to outer sleeve, allows the movement
transmission.
Z Set of centering springs between outer sleeve and
inner rotor.

L. Left control port (steering cylinder)

R. Right control port (steering cylinder)
P. Inlet to steering pump
T. Outlet to oil tank
LS. Outlet to steering pump
 Copyright ©

SECTION 41 - STEERING SYSTEM 13

3.1 TECHNICAL SPECIFICATIONS

Type Sensibility to hydro-static load

Displacement (2WS) 125 cc/rev
Displacement (4WS) 160 cc/rev
Adjustment shock valves (2WS) 200 ÷ 220 bar
Adjustment shock valves (4WS) 240 ÷ 260 bar

TIGHTENING TORQUES
COMPONENT MAXIMUM TIGHTENING TORQUE Nm
3/4 - 16 UNF 60
7/16 - 20 UNF 20
Steering wheel nut 55
Steering motor to steering column bracket 23
Power steering end cover 30
Power steering pipe connection 45
Power steering pipe adaptors 55
Check valve bolt 30
Shock valve (4WS) 30
 Copyright ©

14 SECTION 41 - STEERING SYSTEM

HYDRAULIC DIAGRAM

1. Power steering diagram 4. Anti-shock valve set at 240 ÷ 260 bar

2. Power steering control valve 5. Anticavitation valve
3. Check valve
 Copyright ©

SECTION 41 - STEERING SYSTEM 15

3.2 COMPONENTS

* Only with 4WS models

1. Sleeve 19. Body

2. Spool 20. Ball
3. Ball 21. Pin
4. Thread bushing 22. Check valve
5. O-ring / Roto-Glyd 23. Shock absorbing valve
6. Bearing 24. Dust sealing ring
7. Ring 25. Seat
8. Cross pin
9. Cardan shaft
10. Set of springs
11. O-ring
12. Distributor plate
13. Rotor stator/geart
14. O-ring
15. End cover
16. Washer
17. Special screw
18. Screw
 Copyright ©

16 SECTION 41 - STEERING SYSTEM

3.3 DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
To gain access to the power steering the bonnet and
air cleaner should be removed.

Removing power steering

Disconnect the four connectors and collect the O-
ring seals, noting the connector positions.

Remove the four screws from within the cab.

The power steerin can be removed from the front of
the cab through the engine compartment. Place the
steering unit in the holding tool.

Screw out the screws (18), the screw (17) and the
washers (16) from the end cover (15).
 Copyright ©

SECTION 41 - STEERING SYSTEM 17

Remove the end cover (15), sideways.

Lift the rotor stator/geart (13) (with spacer if fitted) off

the unit. Take out the two O-rings (14).

Remove the cardan shaft (9).

Remove distributor plate (12).

 Copyright ©

18 SECTION 41 - STEERING SYSTEM

Screw out the threaded bush (4) over the check

valve.

Remove O-ring (11).

Shake out the check valve ball (3) and suction valve
pins (21) and balls (20). Replace pins (21) prior to
the reassembly.

Take care to keep the cross pin in the sleeve and

spool horizontal. The pin can be seen through the
open end of the spool. Press the spool inwards and
the sleeve (2), ring, bearing races and needle bear-
ing will be pushed out of the housing together.
 Copyright ©

SECTION 41 - STEERING SYSTEM 19

Take ring (7), bearing races and needle bearing (6)

from sleeve and spool. The outer (thin) bearing race
can sometimes “stick” in the housing, therefore
check that is has come out.

Press out the cross pin (8). Use the special screw
(17) from the end cover. A small mark has been
made with a pumice stone on both spool and sleeve
close to one of the slots for the neutral position
springs (see drawing). If the mark is not visible, re-
member to leave a mark of your own on sleeve and
spool before the neutral position springs are disman-
tled.

Carefully press the spool (1) out of the sleeve (2).

Press the neutral position springs (10) out of their

slots in the spool.
 Copyright ©

20 SECTION 41 - STEERING SYSTEM

Remove dust seal (24) and O-ring / Roto-Glyd (5).

Remove plugs from shock valves using a 6 mm hex-

agon socket spanner.

Remove seal washers.

Unscrew the setting screws using a 6 mm hexagon

socket spanner.
 Copyright ©

SECTION 41 - STEERING SYSTEM 21

Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.

The shock valves (23) are now dismantled.

CLEANING
Clean all parts carefully.

INSPECTION AND REPLACEMENT

Check for signs of wear in the following areas:
Z Rotor and stator of metering unit move freely.
Z Check the drive pin is not cracked or bent.
Z Check the rollers in thrust bearing are free to ro-
tate.
Z Ensure thrust washers are not warped or cracked.
Z Ensure check valve ball is free to move.
Z Check control valve, spool and sleeve for wear or
scoring.
Z Replace all seals and O-ring.

LUBRICATION
Before assembly, lubricate all parts with hydraulic
oil.
 Copyright ©

22 SECTION 41 - STEERING SYSTEM

ASSEMBLY

NOTE: great care should be taken during re-assem-

bly.

Place the two flat neutral position springs in the slot.

Place the curved springs between the flat ones and
press them into place.

Line up the spring set (10).

Guide the spool (1) into the sleeve (2). Make sure
that spool and sleeve are placed correctly in relation
to each other.
 Copyright ©

SECTION 41 - STEERING SYSTEM 23

Assemble spool and sleeve.

When assembling spool and sleeve only one of two
possible ways of positioning the spring slots is cor-
rect. There are three slots in the spool and three
holes in the sleeve in the end of the spool/sleeve op-
posite to the end with spring slots. Place the slots
and holes opposite each other so that parts of the
holes in the sleeve are visible through the slots in the
spool.

Press the springs together and push the neutral po-

sition springs into place in the sleeve.

Line up the springs and centre them.

Guide the ring (7) down over the sleeve.

NOTE: the ring should be able to move - free of

springs.
 Copyright ©

24 SECTION 41 - STEERING SYSTEM

Fit the cross pin (8) into the spool/sleeve.

Fit bearing races and needle bearings (6) as shown

on the next drawing.

1. Spool
2. Sleeve
6. Needle bearings
6A. Outer bearing race
6B. Needle bearing
6C. Inner bearing race

The inside chamfer on the inner bearing race must

face the inner spool.

Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into the
bore for the spool/sleeve.
 Copyright ©

SECTION 41 - STEERING SYSTEM 25

Grease O-ring / Roto-Glyd with hydraulic oil and

place them on the tool.

Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part
of the tool right to the bottom.

Press and turn the O-ring / Roto-Glyd into position in

the housing.

Draw the inner and outer parts of the assembly tool

out of the steering unit bore, leaving the guide from
the inner part in the bore.
 Copyright ©

26 SECTION 41 - STEERING SYSTEM

Lubricate the lip seal (24) with hydraulic oil and place
it on the assembly tool.

Guide the assembly tool right to the bottom.

Press and turn the lip seal into place in the housing.

With a light turning movement, guide the spool and

sleeve into the bore.
Fit the spool set holding the cross pin horizontal.
 Copyright ©

SECTION 41 - STEERING SYSTEM 27

The spool set will push out the assembly tool guide.
The O-ring and Roto Glyd are now in position.

Turn the steering unit until the bore is vertical again.

Put the check valve ball (3) into the hole indicated in
the picture.

Screw the threaded bush (4) lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.

Place a ball (20) in the two holes indicated in the pic-

ture.
 Copyright ©

28 SECTION 41 - STEERING SYSTEM

Place a new pin (21) in the same two holes.

Grease the O-ring (11) with mineral oil.

Place the distributor plate (12) so that the channel

holes match the holes in the housing.

Guide the cardan shaft (9) down into the bore so that
the slot is parallel with the connection flange.
 Copyright ©

SECTION 41 - STEERING SYSTEM 29

Place the cardan shaft (9) as shown - so that it is

held in position by the mounting fork.

Grease the two O-rings and place them in the two

grooves in the gear rim. Fit the rotor stator/geart (13)
and rim on the cardan shaft.

Fit the gearwheel (rotor) and cardan shaft so that a

tooth base in the rotor is positioned in relation to the
shaft slot as shown. Turn the gear rim so that the
seven through holes match the holes in the housing.
 Copyright ©

30 SECTION 41 - STEERING SYSTEM

For precise keying and alignment of steering control

valve, pay attention to the parallelism of (A), (B), (C)
and (D) reference marks.

A. Rotor/stator surface
B. Plate surface
C. Pin axis
D. Housing surface
E. Inner gear case
F. Cardan shaft

Place the end cover (15) in position.

Fit the special screw (17) with washer (16) and place
it in the hole shown.
 Copyright ©

SECTION 41 - STEERING SYSTEM 31

Fit the six screws (18) with washers (16) and insert
them. Cross-tighten all the screws and the rolled pin
with a torque of 30 ± 6 Nm in the sequence shown,
initial torque of 10.8 Nm.

Put a ball in the two holes indicated in the picture.

Place springs and valve cones over the two balls.

Screw in the two setting screws.

 Copyright ©

32 SECTION 41 - STEERING SYSTEM

Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 ± 10 Nm.

Place the dust seal ring (24) in the housing.

Fit the dust seal ring in the housing using the special
tool and a plastic hammer.

PRESSURE TESTING
Connect a suitable pressure gauge capable of read-
ing up to 200 bar to the connector inside the left
hand loader support.
Z Start engine. A standby pressure of 6-7 bar should
be observed.
Z Turn steering to the left or right to the stop. A max-
imum pressure of 180 bar should be seen.

NOTE: engine speed should be set to 1000 rev/min.

 Copyright ©

SECTION 41 - STEERING SYSTEM 33

3.4 SPECIAL TOOLS

P/N CNH DESCRIPTION

380000281 Assembly tool for lip seal.
380002677 Assembly tool for dust seal.
380002679 Assembly tool for cardan shaft.
380002680 Assembly tool for O-ring and Roto-Glyd.

3.5 FAULT FINDING

PROBLEM CAUSE ACTION

No steering or excessive effort Incorrect oil level in tank
required to steer
Air in system
Pump relief valve faulty
Worn pump
Leaking power cylinder
Damaged valve spool
Broken or damaged steering
column
Damaged or worn metering
element
Steering wanders Excessive play in steering
linkage ball joints
Leaking power cylinder
Control valve spool sticking or
worn
Damaged or worn metering
element
Front wheels surge when Leaking power cylinder
steering Control valve spool sticking
Damaged or worn metering
element
Noisy pump Incorrect oil level in tank
Air in system
Water in oil
Worn pump
Fill with the correct grade and
quantity of oil.
Check for loose connections or
damaged tubing. Purge system of
air.
Check system pressure.
Inspect and repair.
Inspect and repair.
Inspect and replace.
Inspect and replace.
Inspect and replace.
Inspect and replace.
Inspect and repair.
Inspect and replace.
Inspect and replace.
Inspect and repair.
Inspect and repair.
Inspect and replace.
Fill with the correct grade and
quantity of oil.
Check for loose connections or
damaged tubing. Purge system of
oil.
Drain and replace the oil.
Replace pump.
 Copyright ©

34 SECTION 41 - STEERING SYSTEM

NOTE:
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 50 - CAB HEATING AND AIR

CONDITIONING

1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING .................................................................................................................................. 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL .............................................................................................................. 47
3.9 COMPRESSOR ................................................................................................................................... 51
3.10 SPECIAL TOOLS............................................................................................................................... 65
 Copyright ©

2 SECTION 50 - CAB HEATING AND AIR CONDITIONING

 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 3

1. TECHNICAL SPECIFICATIONS

HEATING
ENGINE RADIATOR COOLANT
Antifreeze - Ambra Agriflu 12 litres
Water 12 litres
System type Pressurized FULL FLOW by-pass with
expansion chamber
FAN BELT DEFLECTION
Naturally aspired 13 - 19 mm
Turbocharged 10 - 16 mm
THERMOSTAT
Start to open at 82 °C
Fully open at 95 °C
Radiator cap 0.90 bar
TORQUE VALUES
Coolant/hot water hose connections 5 Nm
Air hose ducting connections 5 Nm
Heater housing to floor mounting bolts 6.2 Nm

Refrigerant HFC 134a

Refrigerant charge 1.2 kg
Compressor oil SP20 (PAG Type, Viscosity index 100)
Oil change amount 135 cc

CHECK CONDITIONS
Air inlet temperature 37.8 °C
Rated air inlet moisture 40%
Evaporation temperature 0 °C
Overheating 5 °C
Inlet air speed 1.0 - 2.0 - 3.0 m/s
Condensation temperature 58 °C (absolute 16 bar)
Undercooling 2 °C
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4 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE CALCULATED AT m/s (191.72 m3/h)

Exchanged warmth 5.48 kW 4718.28 kcal/h
Air outlet temperature 5.64 °C
Air side load loss 2.97 daPa 0.30 mmH20
Coolant side load loss 13.1 kPa 0.13 bar
PERFORMANCE CALCULATED AT 2.0 m/s (383.4 m3/h)
Exchanged warmth 9.29 kW 7998.69 kcal/h
Air outlet temperature 10.30 °C
Air side load loss 9.34 daPa 0.95 mmH20
Coolant side load loss 32.7 kPa 0.33 bar
PERFORMANCE CALCULATED AT 3.0 m/s (575.1 m3/h)
Exchanged warmth 12.00 kW 10332.00 kcal/h
Air outlet temperature 13.70 °C
Air side load loss 18.30 daPa 1.87 mmH20
Coolant side load loss 51.20 kPa 0.51 bar
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 5

2. CAB HEATING
2.1 DESCRIPTION AND OPERATION

Cab heating
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the engine
coolant system. A blower motor mounted behind the
cab radiator is used to transfer the heat into the cab.

Heater blower control

The three speed blower is controlled by switch (1)
mounted in the instrument console to the right of the
cab seat. Turn the switch clockwise to the first position
for slow speed. Further rotation of the switch in a clock-
wise direction selects medium and fast speeds. The
blower draws outside air from beneath the cab floor
and through a filter medium into the cab.

Heater temperature control

The temperature of the air from the radiator is adjust-
ed by rotation of the control knob (2) which opens or
closes the radiator valve increasing or decreasing
the water flow as required. Turn the control clock-
wise to increase the temperature of air from the
heater and counter clockwise to reduce the temper-
ature.

SWARNING
The cab air filters are designed to remove dust from
the air but may not exclude chemical vapour. When
working in an enclosed area ensure there is ade-
quate ventilation as exhaust fumes can suffocate
you.

Cab air filter

Before servicing the air filter situated under the driv-
ers seat, switch off the blower and close all windows
and one door. Forcibly close the other door. The re- 3
sulting back pressure will dislodge loose dirt from
the underside of the filters. To remove the filter (3)
release the retaining straps (4) and remove the filter
element. Ensure the element, and sealing faces are
not damaged on removal.

IMPORTANT: in humid conditions, such as occur on

most early mornings, do not switch on the blower pri- 4
or to servicing the filters. Damp particles drawn into F29325

the filter may solidify and prove difficult to remove

without washing.

The filter element is made of specially treated paper

with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar and the air
line nozzle should be at least 300 mm from the ele-
ment.
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6 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Heater radiator
The heater radiator (1) is fitted in a housing under
the cab seat for central displacement of warm or cold
air flow.

IMPORTANT: to ensure a good flow of air through

the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty condi-
tions.

Air flow vents

Air flow vents are connected to the heater container
and receive air from the blower motor, to direct warm
or cold air onto the windscreen and side windows or
to the cab interior as required.
Each vent may be swivelled and adjusted to control
the flow of air.
To open a vent, press one side of the disc and turn
it, as required, to direct the air flow.
The vents are located as follows:
Z two on the top of the main dashboard (A);;
Z two to the rear of the operator seat (A);
Z two under the seat, one in front, the other on the
rear (D);
Z two on the cab posts, right and left (B);

x1 000
Z two on the ceiling, in front and back of operator’s
head (C).

NOTE: the vents (B) and (C) are mounted only when
air conditioned (optional) is fitted.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 7

3 4
2

6
5

F30058

Schematic - Heater system

1. Heater valve mounted to the right of the heater
housing
2. Air ducting to the front windscreen
3. Heater control panel cooler pipes
4. Air ducting to the rear windscreen below the cab
floor
5. Air intake to the heater housing from below the
cab floor
6. Heater pipes to and from heater taken from the
engine oil
 Copyright ©

8 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Electrical heater valve

The electrical valve is equipped with a software that,
each time the supply of the cock is delayed (there-
fore also at backhoe loader start), carries out the mo-
mentary positioning of the cock to “completely
closed” and returns to the position set by the temper-
ature regulation handle located on the control dash-
board. This enables the software to carry out a self-
control on the cock drive so as to always obtain an
optimal regulation of the ball for the water flow.
This is part of the cock normal operation and is not to
be considered as a fault.
Release of the electrical heater valve

IMPORTANT: the release of the valve has to be per-

formed if this valve remains idle for long periods.

Carry out this operation observing the following pro-

cedure:
Z Disconnect the electrical connectors (1).
Z Loosen the screws (2) and take out the electrical
valve (3) from the evaporator.
Z Unscrew and remove screws (4). 3

4
1 2

F30059

Z Separate the driving unit (5) from the cock (6).

Z By means of a wrench turn pin (A) of the cock so as
to unlock it.

SWARNING
5
Once this operation is complete, reset pin (A) in the
correct start position.
6
Reinstall the heater valve, repeating the previous
operation in the reverse order.
A

F30060
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 9

FAULT FINDING - GENERAL

Items that may cause a concern are suggested in
the fault finding chart but as a general rule apply the
following steps:
Ensure water flow to the heater radiator is steady
and all air has been removed from the system.
Hoses are unrestricted and not leaking.
Check the electrical connections are good and the
blower motor is operational.
The operating cable to the heater valve and valve is
operational.

FAULT FINDING

PROBLEM CAUSE ACTION

Dust enters the cab Improper seal around filter element Check seal condition.

Blocked filter Clean or replace filter.

Defective filter Replace filter.

Excessive air leak (s) around doors Repair and Seal air leak(s).
and windows
Blower motor air flow low Blocked filter or recirculation filter Clean or replace filter(s).

Heater radiator core blocked Clean radiator core thoroughly.

Blower motor not working Fuse blown Replace fuse.
Cab does not heat up Engine not reaching operating Replace thermostat.
temperature. Thermostat stuck open

Heater hose from engine to cab
radiator, kinked or blocked
Cab does not cool Heater control turned on
Ensure water flow to heater radiator
is adequate and not restricted.
Turn temperature control knob fully
counterclockwise for maximum
cooling.

Heater control valve stuck in open Free up valve or change as required.

position
Temperature not stable Low engine coolant Top up coolant recovery tank.
 Copyright ©

10 SECTION 50 - CAB HEATING AND AIR CONDITIONING

OVERHAUL

IMPORTANT: when overhauling the heating system

remember that, with the engine running or shortly af-
ter it is turned off, the system will be at engine tem-
perature and therefore the water will be hot and
under pressure.

To effect repairs to the heater core or blower motor,

it will be necessary to remove the attaching bolts (1)
from the seat and remove seat from the heater hous-
ing.

Draining the system

To drain the cooling system down disconnect either
hose at the T junction (2) found at the rear of the en-
gine oil filter mounted to the left hand side of the en-
gine.

F28674

Heater radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the heater radiator (3).
Check water flow through the heater pipe which
should be free running; if not, clear any blockage.
Fins should be free of all debris and not damaged;
clean and or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar taking care not to damage the radi-
ator fins.
Ensure the radiator is not leaking under pressure;
repair or replace as required.
Clean the chamber with a damp, cloth and re-as-
semble the housing filter element with the seal fac-
ing the inside of the cover.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 11

Blower motor
The blower motor (1) can be removed by removal of
the attaching hardware and disconnection of the wir-
ing connector.
Check the blower is working, if not check fuse and
continuity of blower motor. If defective replace the
blower unit as an assembly.

Heater control valve

To service the control valve (2) disconnect the hoses
and the control cable and remove. Check the opera-
tion of the valve and if tight or worn replace.

Heater control panel

The blower motor is operated by a 3 position switch
(3) which through a variable potentiometer increas-
es or decreases voltage to the blower motor.
The heater valve is operated by a control cable
which will push or pull the valve into an open or
closed position.

Both of the above are mounted to the right of the

driver’s seat and can be accessed by removal of the
control panel for repair or replacement.

F28679
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12 SECTION 50 - CAB HEATING AND AIR CONDITIONING

3. AIR CONDITIONING

3.1 PRINCIPALS OF AIR CONDITIONING

The function of the air conditioning system is to im-

prove the operator’s comfort by cooling the air tem-
perature inside the cab and reducing the humidity
level. In order to achieve this heat transfer the follow-
ing principals of heat generation and transfer are ap-
plied within the air conditioning system.
1. When two bodies of different temperature come
together heat is transferred from one to another.
On air conditioning systems an evaporator is
used to hold the low temperature refrigerant
which absorbs the heat from the air within the
cab.
F28680

2. When a gas is pressurized the temperature of

the gas will rise. In air conditioning systems the
increase in pressure is achieved using a com-
pressor.

F28681

3. When a gas is cooled it will condense into a liq-

uid. In the air conditioning system a condenser is
used to cool the gas and the resulting liquid is
stored in a receiver dryer.

F28682
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 13

4. When a liquid is atomized through an orifice, the

temperature of the resultant vapour will lower.
The low temperature of the atomized liquid will
then absorb heat from its surrounding. On air
conditioning systems the refrigerant is atomized
using an expansion valve.
C?

F28683
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14 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Air conditioning principle of operation

1. Expansion valve-atomizes liquid refrigerant be-
fore passing to evaporator
2. Evaporator-absorbs heat from air in cab
3. Compressor-compresses and raises tempera-
ture of refrigerant gas
4. Condenser and receiver dryer-converts refriger-
ant from gas to a liquid
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 15

LOW PRESSURE SIDE HIGH PRESSURE SIDE

EXPANSION
VALVE

LOW
LOWER TEMPERATURE
TEMPERATURE HIGH PRESSURE
LOW PRESSURE LIQUID FILTERED
ATOMIZED LIQUID AND MOISTURE
REMOVED

RECEIVER DRYER

LOWER
TEMPERATURE
EVAPORATOR
HIGH PRESSURE
LIQUID

CONDENSER
WARM LOW
PRESSURE
VAPOUR

HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR

COMPRESSOR

HEAT FROM INSIDE HEAT MOVES TO

CAB MOVES TO OUTSIDE AIR FROM
REFRIGERANT REFRIGERANT

Air conditioning flow diagram

It can now be seen that the principal components of The figure in the this page shows in schematic form
an air conditioning system are: the flow of refrigerant through the five major compo-
Z Refrigerant nents of an air conditioning system.
Z Compressor Refrigerant is drawn into the compressor as a cool,
Z Condenser low pressure vapour which is compressed and then
Z Receiver dryer pumped out as a hot, high pressure vapour to the
Z Expansion valve condenser.
Z Evaporator As the hot, high pressure vapour passes through the
The figure in the previous page uses the examples condenser core it gives off heat to the cooler outside
above to illustrate the air conditioning cycle. air, being drawn past the fins by the engine cooling
fan.

16 SECTION 50 - CAB HEATING AND AIR CONDITIONING
By giving off heat to the outside air, the vapour is
condensed to a liquid which moves under high pres-
sure to the receiver dryer where it is stored until re-
leased to the evaporator by the temperature
sensing expansion valve.
As liquid refrigerant passes through the metered or-
ifice in the expansion valve the refrigerant changes
from a high pressure liquid to a low pressure atom-
ized liquid with a lower temperature.
This low pressure, low temperature, atomized liquid
enters the evaporator coils and absorbs heat from
3.2 SAFETY PRECAUTIONS
SWARNING
Before overhauling an air conditioning system read
and observe the following safety precautions. If a re-
pair or replacement becomes necessary, ensure
that only certified air conditioning technicians are
employed, using approved equipment to effect re-
pairs.
Do not attempt to disassemble the air conditioning
system. It is possible to be severely frostbitten or in-
jured by escaping refrigerant.
IMPORTANT: do not allow refrigerant to escape
into the atmosphere.
Refrigerant must be handled with care in order to
AVOID HAZARDS.
Undue direct contact with liquid refrigerant can pro-
duce freezing of skin and eyes.
Keep the refrigerant container and air conditioning
system away from flame or heat sources; the result-
ing pressure increase can cause the container or
system to explode.
If in direct contact with open flames or heated metal
surfaces, the refrigerant will decompose and pro-
duce products that are toxic and acidic.
Copyright ©
the cab warm air blown across the coils and fins by
the cab blower motor. The refrigerant now changes
from a cold low pressure atomized liquid to a warm
low pressure vapour and leaves the evaporator out-
let, moving to the suction (low pressure) side of the
compressor to repeat the cycle.
As this heat loss is taking place, moisture (humidity)
in the cab air will condense on the outside of the
evaporator and drain off as water through the drain
hoses attached to the evaporator drain pan, thereby
reducing the humidity level of the cab.
Make sure to comply with the following indications
and simple precautions to avoid any risk of injury:
Z Never discharge refrigerant into the atmosphere.
When servicing air conditioning units a certified re-
frigerant recovery unit operated by a certified tech-
nician must be used.
Z When discharging the refrigerant in the system
make sure you are operating in well-ventilated
premises with good air circulation and far away
from open flames.
Z When charging and discharging the system always
wear goggles and take suitable precautions to pro-
tect the face in general and the eyes in particular,
from accidental spillage of the refrigerant fluid.
Z The oil and refrigerant mixture inside the air condi-
tioning system is pressurized. Consequently, nev-
er loosen fittings or tamper with lines unless the
system has been properly discharged.
Z Before loosening any connection, cover the fitting
in question with a cloth and wear gloves and gog-
gles in order to prevent refrigerant from reaching
the skin or eyes.
Z In the event of an accident, proceed as follows:
If the refrigerant has reached the eyes, wash them
immediately with copious amounts of sterilized wa-
ter or mains pressure tap water and transfer to
hospital for immediate medical help.
If the refrigerant has touched the skin, wash with
cold water and transfer to hospital for immediate
medical help.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 17

3.3 DESCRIPTION AND OPERATION

The air conditioning control allows to obtain always

the required clima inside of the cabin.
To activate the air conditioning turn selector (2),
mounted on the control panel to the right of the op-
erator seat. At the activation the warning light (3)
lights up. The selector (1) allows to choose the ideal
temperature according to your requirement. Posi-
tioning selector (1) on “0” and turning selector (2) let
you obtain less or more cold according to the selec-
tor (2) position.
By positioning selector (1) on any other position dif-
ferent from “0” you will obtain instead a mixture of
warm and cold air and the desired clima inside of the
cabin.

NOTE: the air conditioning can be set in to opera-

tion, only if the ventilation selector (4) is not posi-
tioned on STOP.

Turn selector (4) on demand for air capacity.

IMPORTANT: when using the air conditioning, it is

essential that all the windows of the operator’s com-
partment are completely closed.

NOTE: to ensure correct operation and full efficiency

of the air conditioning system, it must be used at
least once a week, even for a short time.

The air-conditioner filter is located on the left hand

side of the seat pod.

SWARNING
The air filter is designed to remove dust from the air
but may not exclude chemical vapour. Refer to
chemical manufacturers directions regarding protec-
tion from dangerous chemicals.

If the machine has been parked in the sun, quicken

the cooling by operating the air-conditioning for 2-3
minutes at its coldest setting. Set maximum blower
speed with a window left partially open to force most
of the warm air from the cab.
With the air cooled sufficiently, close the window and
adjust the controls to the desired temperature. To
ensure proper operation of the system be sure the
cab filter is regularly serviced. Refer to filter mainte-
nance.
It is the normal function of the air-conditioner to ex-
tract water from the air. As such it is possible pools
of water will collect beneath the drain hose outlets
under the cab when the machine is stationary.
 Copyright ©

18 SECTION 50 - CAB HEATING AND AIR CONDITIONING

REFRIGERANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condition-
ing system, requires the use of a suitable “refriger-
ant” a liquid that has a relatively low temperature
boiling point, plus certain desirable safety and sta-
bility features.
The refrigerant used in the air conditioning system is
refrigerant HFC 134a.
NOTE: to help protect the environment legislation
has been introduced in most territories banning the
release into the atmosphere of refrigerants, includ-
ing HFC 134a. All service procedures contained in
this manual can be carried out without the need to
release refrigerant into the atmosphere.
SWARNING
If refrigerant should contact the skin use the same
treatment as for frostbite.
Warm the area with your hand or lukewarm water
32 °C, cover the area loosely with a bandage to
protect affected area against infection and consult
a doctor immediately.
If refrigerant should contact the eyes wash imme-
diately in cold clean water for at least 5 minutes
and consult a doctor immediately.

In order to prevent the incorrect type of refrigerant

being charged to the system the service valves fitted
to the Backhoe Loader and necessary to connect up
refrigerant recovery, evacuation and recycling/re-
charging equipment will be of two different sizes as
recognized and specified by the air conditioning in-
dustry.

SWARNING
HFC 134a refrigerant is not compatible with R-12
refrigerant. Do not attempt to replace HFC 134a re-
frigerant with R-12 refrigerant or test the system us-
ing gauges or equipment previously used with R12
as damage to the system will result.

HFC 134a refrigerant is stable at all operating tem-

peratures and able to absorb great quantities of
heat.
The boiling point of HFC 134a is -22 °C at atmos-
pheric pressure.
If the pressure is increased, HFC 134a will readily
vaporize to absorb heat at temperatures between -
11.7 °C at 1.9 bar and 0 °C at 2.9 bar in the evapo-
rator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 °C at 12.4
bar and 58 °C at 15.85 bar in the condenser.

SWARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the air-
conditioning system as escaping refrigerant can
cause frostbite.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 19

COMPRESSOR
The air conditioning compressor is mounted on the
left hand side of the engine and is belt driven from
the crankshaft pulley.
The compressor separates the low and high pres-
sure sides of the system and has two functions:
1. To raise the refrigerant temperature by com-
pression to a higher degree of temperature than
the ambient (outside air) temperature.
2. To circulate the required volume of refrigerant
through the system.
The refrigerant compressor is a seven cylinder wob-
ble plate unit housed in a die cast aluminium hous-
ing.
Drive to the wobble plate is from the pulley, through
the electro-magnetic clutch to the main driveshaft.
Attached to the driveshaft is a cam rotor which oscil-
lates the wobble plate. The wobble plate is prevent-
ed from rotating by a static gear engaging with teeth
formed in the face of the plate. The seven pistons are
connected to the wobble plate by rods located in ball
sockets.
Refrigerant is drawn in on the downward stroke of a
piston through the reed valves located either end of
the cylinder assembly. Refrigerant enters the cylin-
der assembly through a gallery in the outer circum-
ference of the cylinder assembly.
The upwards stroke of the piston compresses the re-
frigerant and expels it through another reed valve
into an inner gallery in the cylinder assembly and out
into the refrigerant circuit.
The compressor is lubricated with a Polyalklene Gly-
col (PAG) oil Type SP20. This oil is miscible with the
refrigerant and is carried around the refrigerant cir-
cuit.
The compressor is activated by an electro-magnetic
clutch which functions to engage or disengage the
compressor as required in the operation of the air
conditioning system.
The clutch is primarily activated by the:
Z ·Temperature control
Z ·Low pressure cut-out switch
 Copyright ©

20 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Temperature control
The air conditioner temperature control switch is
mounted on the blower motor assembly.
The switch is a device which turns the compressor
clutch on and off to maintain a constant average
evaporator temperature and senses the evaporator
temperature using a thermistor (1).
The temperature control switch compares the volt-
age of the thermistor, which is dependent on the
temperature of the evaporator, with the voltage
across the potentiometer of the “in cab” temperature
control switch.
The switch upon comparing the two voltages deter-
mines whether the compressor clutch should be
switched “on” or “off” in order to maintain the desired
in cab temperature control.

Low pressure cut-out switch

The low pressure switch (1) is mounted in the top of
the filter (2) mounted in front of the radiator behind
the battery.
The purpose of the switch is to shut off the compres-
sor pump in the event of low pressure in the refriger-
ant system.
Low refrigerant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve or-
ifice or refrigerant loss. Low refrigerant pressure
may result in damage to the compressor pump.
The low pressure switch is factory set and cannot be
adjusted.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 21

CONDENSER
The condenser (1), located at the front of the ma-
chine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a se-
ries of thin cooling fins to provide a maximum of heat
transfer in a minimum amount of space.

NOTE: the condenser after removal of the attaching

bolts can be slid out for cleaning.

The condenser receives the hot, high pressure re-

frigerant vapour from the compressor. The hot va-
pour passes through the condenser coils and
outside air is drawn through the condenser by the
engine cooling fan.
Heat moves from the hot refrigerant vapour into the
cooler outside air flowing across the condenser coils
and fins.
When the refrigerant vapour reaches the pressure
and temperature that will induce a change of state, a
large quantity of heat is transferred to the outside air
and the refrigerant changes to a high pressure warm
liquid.
The warm liquid refrigerant continues onto the re-
ceiver/drier where it is filtered and desiccated, to re-
move any moisture, before passing through an
outlet line to the thermostatic expansion valve.

RECEIVER DRYER
The receiver/dryer (2) situated behind the battery
stores the liquid refrigerant to be sure a steady flow
to the thermostatic expansion valve is maintained
under widely different operating conditions.
The drier section contains a desiccant (Molecular
sieve) to absorb any moisture within the system and
a filter prevents the entry of foreign particles.

NOTE: any moisture in the air conditioning system is

extremely harmful. Moisture not absorbed by the de-
hydrator will circulate with the refrigerant and drop-
lets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the re-
frigerant flow and stop the cooling action. Moisture
will also react with refrigerant HFC 134a and the lu-
bricant to form a corrosive acid.

The desiccant can only absorb a limited amount of

moisture before reaching saturation point. Because
of this, after any system component replacement or
repairs requiring entry into the system, the receiver/
dryer should be replaced.
 Copyright ©

22 SECTION 50 - CAB HEATING AND AIR CONDITIONING

EXPANSION VALVE
The expansion valve (1) is located underneath the
evaporator in the pressure line leading from the re-
ceiver/ dryer and performs the following unctions:
1. METERING ACTION
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liq-
uid.
2. MODULATING ACTION
A thermostatically controlled valve within the ex-
pansion valve body controls the volume of liquid
refrigerant passing through the orifice and
makes sure the refrigerant is fully vaporized
within the evaporator. Liquid refrigerant at would
damage the compressor reed valves or freeze
the pistons.
3. CONTROLLING ACTION
The valve responds to changes in the cooling re-
quirements. When increased cooling is required,
the valve opens to increase the refrigerant flow
and when less cooling is required the valve clos-
es and decreases the refrigerant flow.

Expansion valve - operation

All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic
unit and no external tubes are required for these pur-
poses.
The refrigerant from the condenser and receiver dry-
er enters the thermostatic expansion valve as a high
pressure warm liquid. Upon passing through the ball
and spring controlled metering orifice, the pressure
and temperature of the refrigerant is reduced and
the refrigerant leaves the thermostatic expansion
valve as a low pressure, lower temperature atom-
ized liquid. F28691

The atomized liquid now passes through the evapo-

rator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour. There are two refrigerant passag-
es in the valve. One passage is in the refrigerant line
from the condenser to the evaporator and contains
the ball and spring type orifice valve.
The other passage is in the refrigerant line from the
evaporator to the compressor and contains the
valve’s temperature sensing element.
Liquid refrigerant flow from the condenser and re-
ceiver dryer is controlled by a push-rod forcing the
orifice valve ball off its seat and the spring exerting
pressure on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the
pressure on the bottom of the expansion valve dia-
phragm rises above the pressure on the top of the di-
aphragm allowing the valve spring to close the
orifice.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 23

When the system is started, the pressure on the bot-

tom of the diaphragm lowers rapidly, allowing the or-
ifice to open and metre atomized liquid refrigerant to
the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized
refrigerant out of the evaporator and back through a
gallery in the top of the valve which asses the tem-
perature sensor.
The temperature sensor reacts to variations in refrig-
erant gas pressure returning from the evaporator.
When heat from the passenger compartment is ab-
sorbed by the refrigerant the pressure of the gas in-
creases causing a differential pressure above and
below the temperature sensor diaphragm. The dia-
phragm reacts to this pressure differential and a
push rod forces the ball in the expansion valve orifice
further off its seat. This reaction allows an increase
in the atomized refrigerant to flow through the valve,
to the evaporator, so that more heat can be absorbed
by the air conditioning system.
Similarly when the temperature of the gas returning
from the evaporator decreases the pressure of the
gas decreases. This causes the diaphragm to react
accordingly and allow the ball in the orifice to move
closer towards its seat thus reducing the flow of re-
frigerant through the valve to the evaporator.
 Copyright ©

24 SECTION 50 - CAB HEATING AND AIR CONDITIONING

EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator ab-
sorbs heat from the hotter air in the operator’s com-
partment, thereby cooling the air.

Air Recirculation
An intake grille is located on the left side of the seat
base. A portion of the air flow will recirculate through
the evaporator.

Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recircula- 2
tion grille (1). The air passes over the evaporator
then into the cab through the six louvered vents.
Two vents are located on the front instrument panel
to direct air onto the windshield. Two are located at
the base of the rear posts to direct air onto the rear
window. Two additional vents are located at the front
and rear of the seat base to direct air at the opera- 1
tor’s feet.
F29327

Blower Fan
The blower motor is controlled by a three-speed
switch (3) which uses a variable resistor to change
the fan speed.
High blower speed provides the greatest volume of
circulated air, however, a slower speed will allow the
air to contact the cooling fins and coils of the evapo-
rator for a longer period resulting in the warm air giv-
ing up more heat to the cooler refrigerant. Therefore,
the coldest air temperature is obtained when the
blower fan is operated at the lowest speed.

SECTION 50 - CAB HEATING AND AIR CONDITIONING
3.4 FAULT FINDING AND TESTING
Overhaul of the air conditioning system should only
be undertaken by a certified specialist refrigeration
engineer using a comprehensive air conditioning
test kit, including a gas leak detector, suitable for
HFC 134a refrigerant gas.
SWARNING
Before dismantling an air conditioning system for re-
pair the gas within the system must be discharged
and recovered using a certified recovery unit de-
signed for the type of refrigerant gas used in the sys-
tem.
NEVER release refrigerant gas into the atmos-
phere.
ALWAYS wear safety goggles and gloves when
servicing any part of the air conditioning system.
To prevent the entry of any foreign material, observe
the following points:
Z Ensure all tools, gauges, hoses and replacement
parts are kept clean and dry and are suitable for
the type of refrigerant gas used in the system.
Z Clean all hoses and fittings before disconnecting.
Z Cap or plug all openings when disconnected.
Z When adding lubricating oil to the system always
uncap and re-cap the oil container immediately be-
fore and after use. Always ensure the oil remains
free of moisture.
Copyright ©
25
Preliminary fault finding
Always conduct the preliminary fault finding checks
before performance testing the system.
1. Run the engine at 1000-1200 rev/min for 10
minutes with the air conditioner set at maximum
cooling and the blower on high speed.
2. Check that the heater temperature control is
switched OFF.
3. Check that the blower fan is operating at all
speeds.
4. Check that the compressor clutch engages
when the temperature control switch is turned
from “OFF” to “ON” position. A clicking sound in-
dicates the clutch is engaging. If the clutch fails
to operate it may indicate an electrical problem
in the high low pressure cut out switches or mal-
function of the electrical drive clutch on the com-
pressor.
5. Check the engine cooling fan is drawing cool air
through the condenser.
6. Check the compressor drive belt tension.
7. Check the condenser core and grid is clean and
free of obstruction.
8. Check the cab air filter is clean and free of ob-
struction.
9. Check the evaporator fins are not plugged or ex-
cessively dirty.

26 SECTION 50 - CAB HEATING AND AIR CONDITIONING
Attaching Manifold Gauge Set to the Tractor
1. Low Side Gauge
2. High Side Gauge
3. Shut-off Valve
4. Test Hose to High Side Service Connector
5. Centre Hose (Not Used)
Performance Testing The Air Conditioning Sys-
tem
The manifold gauge set is the most important tool
used in testing and servicing the air conditioning
system.
NOTE: for Dealers who posses the latest design
level of refrigerant recovery, recycling and recharg-
ing station, these gauges are an integral part of the
machine.
The following instructions for performance testing
the air conditioning system is based on the use of
the gauge set shown. The principal of operation is
however similar when testing the system using a re-
covery and recharging station with integral gauges.
When using this type of equipment always consult
the manufacturers operating instructions.
Copyright ©
6. Test Hose to Low Side Service Connector
7. Shut-off Valve
8. Low Pressure (Suction) Side Service Valve
9. High Pressure (Discharge) Side Service Valve
Operating Precautions
IMPORTANT: always ensure the shut-off valves are
closed (turn clockwise until seated) during all test
operations.
In the closed position, refrigerant circulates around
the valve stems to the gauges. Therefore, when the
manifold gauge set is connected into a system,
pressure is registered on both gauges.
Z NEVER open the HIGH SIDE shut off valve when
the system is operating.
Z ALWAYS open the LOW SIDE shut off valve when
adding refrigerant.

SECTION 50 - CAB HEATING AND AIR CONDITIONING
Attaching The Gauge Set To The Tractor
SWARNING
To avoid personal injury, stop the tractor engine dur-
ing connection of the manifold gauge set.
1. Check that the gauge set shut off valves are
closed (turned fully clockwise).
2. Connect the high side gauge hose (normally
red) to the high pressure (discharge) side serv-
ice valve and the low side gauge hose (normally
blue) to the low pressure (suction) side service
valve on the tractor. Ensure the hose connec-
tions are fully tightened.
IMPORTANT: prior to connection of the manifold
gauge set, identify the suction (low pressure) and
discharge (high pressure) service gauge ports. The
high pressure service valve is always in the line from
the compressor to the condenser.
The high and low pressure service valves on the
tractor are spring loaded valve and will be automat-
ically opened when the test hose is connected.
NOTE: the test hose must incorporate a valve de-
pressor to actuate this type of valve.
The service valves have a protective cap. This cap
must be removed for test gauge connections and re-
placed when service operations are completed.
Test Procedure
After the manifold gauge set has been connected
and before pressure tests can be made, the system
must be stabilized as follows:
1. Apply the parking brake, check the gear shift le-
vers are in neutral and close the cab windows
and doors.
APPROXIMATE HIGH PRESSURE GAUGE READINGS
Ambient air temperature
Degrees C bar
27 10.0/11.6
29 11.2/12.7
32 12.3/13.8
35 13.3/15.2
38 14.5/16.7
41 16.0/18.3
43 17.3/20.0
Copyright ©
27
2. Re-check that both the high and low side shut
off valves on the manifold gauge set are fully
closed.
3. Run the engine at 1000-1200 rev/min.
4. Turn the heater temperature control “off”.
5. Operate the system at maximum cooling, with
the blower fan at high speed for 10 minutes to
stabilize all components.
6. Check the manifold low pressure gauge reading
is within the specified range of approximately
0.28-2.48 bar.
7. Check the manifold high pressure gauge read-
ing and compare the reading to the pressure in-
dicated on the pressure temperature chart
below.
8. Measure and compare the temperature of con-
ditioned air entering the cab through the lou-
vered air vents with the ambient air at the air
intake filters on the outside of the cab.
If the system is operating correctly the condi-
tioned air entering the cab should be 6-9 °C
cooler than the ambient temperature of the out-
side air.
9. If it is confirmed that the system is not operating
correctly refer to the fault diagnostic charts and
performance test gauge reading examples on
the following pages for possible corrective ac-
tion.
SWARNING
A significant amount of refrigerant vapour may have
condensed to a liquid at the service fitting at the high
side of the compressor. Use a cloth or other protec-
tive material when disconnecting the manifold hose
from this fitting to prevent personal injury to hands
and face.
High pressure gauge reading
kgf/cm2
10.3/11.8
11.4/12.9
12.5/14.0
13.6/15.5
14.8/17.0
16.3/18.6
17.7/20.3
 Copyright ©

28 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST DIAGNOSIS

Gauge Readings: Low Pressure - Low

High Pressure - Low

PROBLEM POSSIBLE CAUSE CORRECTION

Evaporator air not cold Low refrigerant charge Perform leak tests and repair.

Evacuate system.

Charge system, re-test system.

Evaporator air warm Extremely low refrigerant charge Perform leak tests and repair.

Evacuate system.

Charge system, re-test system.

Evaporator air cool but not
sufficiently cold
Low pressure switch cutting
out
Expansion valve to evaporator
tube shows considerable
condensation or frost
Too cold to touch
Expansion valve not permitting Check expansion valve as follows:
sufficient flow
Stuck valve Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge system.
Replace expansion valve.
Evacuate system.
Charge system.
Re-test.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 29

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings: Low Pressure - High

High Pressure - High

PROBLEM POSSIBLE CAUSE CORRECTION

Evaporator air warm
Liquid line hot (condenser
outlet to expansion valve
tube)
Improper operation of condenser
Inspect for dirty condenser
restricting air flow and cooling.
Check operation of condenser
cooling fans. Repair or replace as
needed.

High pressure switch cutting
out
Evaporator air not cold
Overcharged with refrigerant
Air in system
Expansion valve allowing too much
refrigerant to flow through the
evaporator
Check for overcharge as follows:
Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the system with the
correct quantity of refrigerant,
replacing any lost lubricant. Recheck
performance of air conditioning
system.
Check expansion valve as follows:
Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge System.
Replace Expansion Valve.
Evacuate System.
Charge System.
Re-test.

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings: Low Pressure - Low

High Pressure - High

PROBLEM POSSIBLE CAUSE CORRECTION

Insufficient cooling
Restriction in liquid line
Discharge the system.
Replace the receiver/drier.
Inspect all lines and tubing from
compressor outlet to expansion
valve.
Replace if needed.
Evacuate the system.
Charge the system.
Re-test.
 Copyright ©

30 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings: Low Pressure - High

High Pressure - Low

PROBLEM POSSIBLE CAUSE CORRECTION

Evaporator air not cold
Internal leak in compressor (reed
valves, gasket, worn or scored
piston rings or cylinder)
Discharge the system.
Replace the compressor.
Evacuate the system.
Charge the system.
Re-test.

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings: Low Pressure - Normal

High Pressure - Normal

PROBLEM POSSIBLE CAUSE CORRECTION

Insufficient cooling
Low pressure reading does
not fluctuate with changes in
temperature control switch
(pressure should lower until
compressor cycles)
Evaporator air not cold
System low on charge. Air or Perform leak test.
moisture present in system Discharge system.
Repair leaks.
Replace receiver/drier.
Check oil level.
Evacuate system.
Charge the system.
Re-test.

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings: Low Pressure - High

High Pressure - Normal

PROBLEM POSSIBLE CAUSE CORRECTION

Compressor cycles “on” and Defective temperature control Stop engine and shut off A/C.
“off” too frequently (thermostatic) switch Replace temperature control switch.
Re-test system and check
compressor cycling.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 31

EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS

The following examples show typical low and high pressure gauge readings obtained when performance test-
ing the air conditioning system with an ambient temperature of 35 °C.
The recommended corrective action is based on a similar fault as identified in the performance test diagnosis
charts.

PERFORMANCE TEST EXAMPLE 1

7 1

6 2

5 4 3
F28697

Performance Test Example 1

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used

PROBLEM 3. Check compressor oil to ensure no loss.

Little or no cooling. 4. Evacuate the system.
5. Charge the system.
CAUSE 6. Performance test the system.
Refrigerant slightly low.
DIAGNOSIS
CONDITIONS* System refrigerant is low. May be caused by a small
Low side pressure too low. leak.
Gauge should read 1-2 bar.
NOTE: * test procedure based upon ambient tem-
High side pressure too low. perature of 35 °C.
Gauge should read 13.3-14.8 bar. For proper high side gauge reading for other ambi-
Evaporator air not cold. ent temperatures, refer to the pressure temperature
chart.
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Repair leaks. (Discharge and recover the refrig-
erant from the system; replace lines or compo-
nents).
 Copyright ©

32 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST EXAMPLE 2

7 1

6 2

5 4 3
F28698

Performance Test Example 2

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side normal
4. Not used

PROBLEM DIAGNOSIS
Insufficient cooling. System refrigerant is extremely low. A serious leak
is indicated.
CAUSE
Refrigerant excessively low. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
CONDITIONS* For proper high side gauge reading for other ambi-
Low side pressure very low. ent temperatures, refer to the pressure temperature
Gauge should read 1-2 bar. chart.

High side pressure too low.

Gauge should read 13.3-14.8 bar.

Evaporator air warm.

Low pressure switch cutting out.

CORRECTIVE PROCEDURES
1. Leak test the system.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Check compressor oil to ensure no loss.
5. Evacuate the system.
6. Charge the system.
7. Performance test the system.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 33

PERFORMANCE TEST EXAMPLE 3

7 1

6 2

5 4 3
F28699

Performance Test Example 3

1. High side normal 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used

PROBLEM 2. Discharge and recover the refrigerant from the

Insufficient cooling. system.
3. Repair leaks.
CAUSE 4. Replace the receiver/dryer.
Air in system. 5. Check compressor oil to ensure no loss.
6. Evacuate the system.
CONDITIONS* 7. Charge the system.
Low side pressure reading does not change when 8. Performance test the system.
compressor cycles “ON” and “OFF”.
DIAGNOSIS
High side pressure slightly high or slightly low. Air or moisture in system. System not fully charged.
Gauge should read 13.3-14.8 bar.
NOTE: * test procedure based upon ambient tem-
Evaporator air not cold. perature of 35 °C.
For proper high side gauge reading for other ambi-
CORRECTIVE PROCEDURES ent temperatures, refer to the pressure temperature
1. Leak test the system. Give special attention to chart.
the compressor seal area.
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34 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST EXAMPLE 4

7 1

6 2

5 4 3
F28700

Performance Test Example 4

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side high
4. Not used

PROBLEM CORRECTIVE PROCEDURES

Insufficient cooling. 1. Replace the compressor.

CAUSE DIAGNOSIS
Compressor malfunction. Internal leak in compressor caused by worn or
scored pistons, rings, or cylinders.
CONDITIONS*
Low side pressure too high. Gauge should read 1-2 NOTE: * test procedure based upon ambient tem-
bar. perature of 35 °C.
For proper high side gauge reading for other ambi-
High side pressure too low. Gauge should read ent temperatures, refer to the pressure temperature
13.3-14.8 bar. chart.

Evaporator air not cold.

 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 35

PERFORMANCE TEST EXAMPLE 5

7 1

6 2

5 4 3

F28701

Performance Test Example 4

1. High side high 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side high
4. Not used

PROBLEM
Insufficient or no cooling. Engine overheats in some
cases.
CAUSE
Condenser not functioning properly.
CONDITIONS*
Low side pressure too high. Gauge should read 1-2
bar.
High side pressure too high. Gauge should read
13.3-14.8 bar.
Liquid line hot.
Evaporator air warm.
High pressure switch cutting out.
CORRECTIVE PROCEDURES
1. Check belt. Loose or worn drive belts could
cause excessive pressures in the compressor
head.
2. Look for clogged passages between the con-
denser fins and coil, or other obstructions that
could reduce condenser airflow.
3. If engine is overheating replace engine thermo-
stat and radiator pressure cap.
At this point, operate the system and check its per-
formance. If still unsatisfactory, proceed as follows:
4. Discharge and recover the refrigerant from the
system.
5. Remove the condenser and clean and flush it to
ensure a free flow of refrigerant. Or, if the con-
denser appears to be unduly dirty or plugged,
replace it.
6. Replace the receiver/dryer.
7. Evacuate the system, and recharge it with the
correct quantity of refrigerant.
8. Performance test the system.
DIAGNOSIS
Lack of cooling caused by pressure that is too high
on the high side, resulting from improper operation
of condenser. (Refrigerant charge may be normal or
excessive).
NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
 Copyright ©

36 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST EXAMPLE 6

7 1

6 2

5 4 3

F28701

Performance Test Example 6

1. High side normal 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side normal
4. Not used

PROBLEM CORRECTIVE PROCEDURES

Insufficient or no cooling. 1. Discharge and recover the refrigerant from the
system.
CAUSE 2. Replace the receiver/dryer.
Large amount of air in system. 3. Evacuate the system.
4. Charge the system.
CONDITIONS* 5. Performance test the system.
Low side pressure too high. Gauge should read 1-2
bar. DIAGNOSIS
Air in system. This, and the moisture in the air, is
High side pressure too low. Gauge should read contaminating the refrigerant, causing the system to
13.3-14.8 bar. operate improperly.

Evaporator air not cold. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 37

PERFORMANCE TEST EXAMPLE 7

7 1

6 2

5 4 3

F28704

Performance Test Example 7

1. High side high 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side hide
4. Not used

PROBLEM 2. If the test indicates that the expansion valve is

Insufficient or no cooling. defective, proceed as follows:
Discharge and recover the refrigerant from the
CAUSE system.
Improper operation of thermostatic expansion valve Replace the expansion valve.
(stuck open). Evacuate the system.
Charge the system.
CONDITIONS* Performance test the system.
Low side pressure too high. Gauge should read 1-2
bar. DIAGNOSIS
Thermostatic expansion valve is allowing too much
High side pressure too high. Gauge should read refrigerant to flow through the evaporator coils.
13.3-14.8 bar. Valve may be stuck open.

Evaporator air warm. NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
Evaporator and suction hose (to compressor) sur- For proper high side gauge reading for other ambi-
faces show considerable moisture. ent temperatures, refer to the pressure temperature
chart.
CORRECTIVE PROCEDURES
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
 Copyright ©

38 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST EXAMPLE 8

7 1

6 2

5 4 3

F28705

Performance Test Example 8

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used

PROBLEM Check the low side gauge. The pressure should

Insufficient cooling. lower slowly.
2. If the procedure outlined in Step 1 shows that
CAUSE the expansion valve is defective, proceed as fol-
Improper operation of thermostatic expansion valve lows:
(stuck open). Discharge system.
Replace the expansion valve.
CONDITIONS* Evacuate the system.
Low side pressure too low (zero or vacuum). Gauge Charge the system.
should read 1-2 bar. Performance test the system.
High side pressure low. Gauge should read 13.3- DIAGNOSIS
14.8 bar. Expansion valve is not permitting a sufficient flow of
refrigerant. May be caused by valve stuck in restrict-
Evaporator air cool, but not sufficiently cold. ed or closed position.
Evaporator inlet pipe surface shows considerable NOTE: * test procedure based upon ambient tem-
moisture or frost. perature of 35 °C.
For proper high side gauge reading for other ambi-
Low pressure switch cutting out.
ent temperatures, refer to the pressure temperature
CORRECTIVE PROCEDURES chart.
1. Place finger on expansion valve to evaporator
tube. If too cold to touch, proceed as follows:
Operate the system at maximum cooling.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 39

PERFORMANCE TEST EXAMPLE 9

7 1

6 2

5 4 3

F28706

Performance Test Example 9

1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used

PROBLEM CORRECTIVE PROCEDURES

Insufficient or no cooling.
CAUSE
Restriction in high side of system.
CONDITIONS*
Low side pressure too low. Gauge should read 1-2
bar.
High side pressure too low. Gauge should read
13.3-14.8 bar.
NOTE: a normal or high reading of the high side
pressure gauge under these conditions indicates
the system is overcharged or the condenser or re-
ceiver/dryer is too small.
Evaporator only slightly cool.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
2. If the test indicates that the expansion valve is
defective, proceed as follows:
Discharge and recover the refrigerant from the
system.
Replace the expansion valve.
Evacuate the system.
Charge the system.
Performance test the system.
DIAGNOSIS
Thermostatic expansion valve is allowing too much
refrigerant to flow through the evaporator coils.
Valve may be stuck open.
NOTE: * test procedure based upon ambient tem-
perature of 35 °C.
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
 Copyright ©

40 SECTION 50 - CAB HEATING AND AIR CONDITIONING

PERFORMANCE TEST EXAMPLE 10

7 B A 1

6 2

5 4 3

F28707

Performance Test Example 10

1. High side normal 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side gauge
4. Not used Compressor cycles on at 2.3 bar
Compressor cycles off at 1.9 bar

PROBLEM 3. Make sure the switch’s temperature sensor is in-

Compressor cycles (cuts in and out) too rapidly. stalled in the same position and depth (in evap-
orator core) as previous.
CAUSE 4. Performance test the system.
Thermostatic switch defective.
DIAGNOSIS
CONDITIONS* Defective thermostatic switch.
Low side pressure readings too high during both
“ON” and “OFF” compressor cycles and between NOTE: * test procedure based upon ambient tem-
cycles. perature of 35 °C.
Readings should be: For proper high side gauge reading for other ambi-
0.8-1.0 bar - cycle “OFF” ent temperatures, refer to the pressure temperature
2.5-2.7 bar - cycle “ON” chart.
1.7-1.9 bar - between cycles

High side pressure normal. Gauge should read

13.3-14.8 bar.

CORRECTIVE PROCEDURES
1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
type.
 Copyright ©

SECTION 50 - CAB HEATING AND AIR CONDITIONING 41

LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM

Leak Testing
To perform a leak test if refrigerant leakage is sus-
pected, use a leak detector following the manufac-
turer’s instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the manufactur-
er’s instructions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley
area is normal and does not necessarily indicate a
repair is required. F28708

When a leak is located, follow these steps.

Z Discharge the system using a certified refrigerant
recovery system.
Z Repair the leak.
Z Evacuate the system.
Z Partially charge system with 400 gr of refrigerant.
Z Check system for leaks.
Z Fully charge the system.
Always check the system for leaks as a final test af-
ter evacuating and before recharging. Refer to
“Evacuating the system”.

Discharging the system

Legislation has been introduced banning the release
of refrigerant into the atmosphere.
Whenever overhauling the air conditioning system
or performing other tasks which require the air con-
ditioning system to be dismantled it is necessary to
discharge the refrigerant gas before commencing
repair.
Before you can dismantle an air conditioning system
for repairs, you must discharge and recover the re-
frigerant using a certified recovery unit in accord-
ance with the manufacturers instructions.
Shown is a combined refrigerant recovery, evacua-
tion and recycling/charging station. This equipment
removes HFC 134a refrigerant from the air condi-
tioning system, recycles and recharges all in one
hook up.
The unit is designed to be used with the manifold
gauge set built into the control panel.

F28709
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42 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Connecting recovery evacuation and recycling/charging station to the tractor

1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)

Other recovery systems are available where the
manifold gauges are not an integral part of the ma-
chine. When this type of equipment is used a sepa-
rate manifold gauge set must be used.
The following is a summary of the steps for dis-
charging the system using a recovery/recycling unit.
SWARNING
Never discharge refrigerant gas into the atmos-
phere. Always wear safety goggles and gloves
when working with refrigerant. Only use authorized
refrigerant tanks.
IMPORTANT: always follow the manufactures in-
structions when operating recovery equipment.
tractor air conditioning system. The hose from the
recovery unit is then connected to the manifold cen-
tre port.
3. To recover refrigerant, open both high and low
side valves on the control panel or the valves on
the manifold gauge set if being used.
4. Open the valves labelled “gas” and “liquid” on
the recovery unit refrigerant tank.
5. Plug in the unit’s power cord.
6. Operate the recovery system in accordance with
the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.

1. Run the vehicle’s air conditioning system for a

few minutes.
2. Set up the recovery unit following manufactur-
er’s instructions. Ensure that the units red (high
side) hose is connected to the high side (dis-
charge) fitting and the blue (low side) hose to
the low side (suction) fitting.

NOTE: if a unit requiring the manifold gauge set is

being used, the low and high sides of the manifold
set are connected to the low and high sides of the
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 43

3.5 FLUSHING THE SYSTEM

7 1

6 2

5 4 3
F28711

Manifold side gauge

1. High side gauge 5. Low side hose
2. High side shut-off valve 6. Low side shut-off valve
3. High side hose 7. Low side gauge
4. Centre service hose

Air conditioning systems may occasionally become

contaminated with solid particles. This contamina-
tion may be the result of allowing dirt to enter the
system while it was open, from aluminium corrosion
or sludge, or from disintegrated compressor reed
plates. Contamination of this nature can result in
plugged evaporators, condensers and expansion
valves.

Flush System with dry nitrogen.

Each individual component must be flushed after

disconnecting every hose fitting.

The compressor and expansion valve can not be

flushed, therefore, the compressor should be disas-
sembled and cleaned or replaced and the expan-
sion valve should be replaced. When flushing the
system always replace the receiver/drier.
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44 SECTION 50 - CAB HEATING AND AIR CONDITIONING

NOTE: never use any solvent for flushing an air con-

ditioning system other than a special flush solvent
made specifically for air conditioning systems. Al-
ways follow the manufacturer’s recommendations
and directions for using the flushing equipment and
solvent.

Re-assemble and evacuate the system to remove

air and moisture as described in “Evacuating the
System”.

F28712
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 45

3.6 EVACUATING THE SYSTEM

Fully open both the low and high side gauge

IMPORTANT: a system in which the refrigerant has shut off valves.
been recovered to facilitate repairs, must be evacu- 2. If a combined recovery/evacuation unit is to be
ated before new refrigerant is installed. used attach the unit to the air conditioning sys-
tem in accordance with the manufacturers in-
Air and moisture are removed by evacuating the structions. Be sure to read all installation and
system using a vacuum pump. operating instructions carefully before starting
The automatic recycling, recharge and evacuation the unit.
stations or evacuating and charging stations availa- 3. After starting the evacuation cycle, note the low
ble throughout the air conditioning industry incorpo- side gauge to be sure the system pulls down
rate a vacuum pump within the assembly. If this type into a vacuum.
of equipment is not available a separate vacuum 4. Time the evacuation for a minimum of 30 min-
pump and manifold gauge set must be used. utes from the point when lowest vacuum is at-
As the system is evacuated the boiling point of any tained.
moisture within the system is similarly lowered. As 5. Thirty minutes later when the low side gauge at-
the vacuum increases the boiling reduces to below tains the lowest steady vacuum, stop the evac-
that of the ambient temperate and the moisture is uation process.
subsequently boiled away.
The relationship of system vacuum to the boiling NOTE: the vacuum pump achieves ultimate vacu-
temperature at which the water vapour is removed um with the vented exhaust valve closed. Do not
from the system is as follows: evacuate too quickly as oil may be drawn from the
system.
System System 6. Check the system by closing the gauge shut-off
Temperature
Vacuum Vacuum valves, turning the vacuum pump off and noting
In In Cm. of the low side gauge reading. A loss of more than
°C 5 cm of vacuum in 5 minutes indicates either a
Mercury Mercury
leak or moisture in the system.
28.0 71.0 38 7. If the gauge needle remains stationary and the
28.9 73.4 27 vacuum is maintained for 3-5 minutes, close
both the high and low side manifold hand
29.4 74.6 16 valves, turn off and disconnect the centre hose
29.7 75.4 5 from the pump. The system is now ready for
charging.
29.8 75.7 -7 8. If a leak is detected, charge the system with ap-
29.9 75.9 -18 proximately 400 g of refrigerant, see charging
the system and locate the leak using a leak de-
tector.
9. Once the leak is located discharge and recover
NOTE: for every 305 m above sea level, the vacuum
the refrigerant in the system, repair the leak,
gauge reading must be corrected by adding 2.54 cm
then repeat the evacuation procedure.
of mercury to compensate for the change in atmos-
pheric pressure.

IMPORTANT: be sure the system is completely dis-

charged as refrigerant will damage the vacuum
pump.

1. If the manifold gauge set is being used connect

the low and high sides of the manifold to the low
and high sides of the vehicle air conditioning
system as described for discharging the system.
Connect the manifold centre hose to the vacu-
um pump suction port as per the manufacturers
instructions.

46 SECTION 50 - CAB HEATING AND AIR CONDITIONING
3.7 CHARGING THE SYSTEM
IMPORTANT: be sure there are no leaks in the sys-
tem and the system has been fully evacuated. Ob-
serve all safety recommendations when handling
refrigerant HFC 134a, see “Precautions when Han-
dling Refrigerant HFC 134a” in this Section.
1. Ensure the charging unit is correctly connected
to the tractor air conditioning system in accord-
ance with the manufacturers instructions.
2. If a charging unit, in conjunction with the mani-
fold gauge set is used, open the high and low
side hand valves on the manifold.
3. Charge the system with 0.75 kg of refrigerant as
per the manufacturers instructions.
4. If the charging rate becomes very slow close
the high side valve carefully, start the tractor
and set engine speed to idle. Turn ON the air
Connecting recovery evacuation and recycling/charging station to the tractor
1. Built in manifold gauge set
2. Recovery/recharging unit
Copyright ©
conditioning so that the compressor can pull the
remainder of the refrigerant into the system.
5. If the refrigerant charge will not completely
transfer to the air conditioning system, recover
and recharge the system.
6. Close the high and low side valves on the units
control panel, or manifold gauge set if being
used and test the air conditioning as detailed in
Performance testing the air conditioning system
on page 25.
NOTE: after charging a system use the following
start up procedure to ensure the lubricating oil is
properly dispersed around the system.
Z Ensure air conditioning is switched OFF.
Z Start the engine and bring speed down to idle.
Z Turn the air conditioning ON and allow system to
operate for at least one minute before increasing
engine speed.
3. Low side (suction) service valve (blue hose)
4. High side (discharge) service valve (red hose)
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 47

3.8 COMPONENTS OVERHAUL

GENERAL

SWARNING
Before disconnecting components in the air condi-
tioning system the refrigerant gas must be dis-
charged and recovered using a certified recovery
system. Refer to Discharging the system. Do Not
discharge the gas into the atmosphere.

If an air conditioning component is to be replaced

during a system overhaul it is necessary to drain any
refrigerant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean refrigerant oil equivalent to that re-
moved from the replaced component must then be
added to the new item before being installed onto the
tractor.
Upon completion of the repair evacuate, recharge,
leak test and performance test the system to ensure
correct operation.

EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
1. Fully discharge the air conditioning system.
2. Remove the seat to gain access to the valve.
3. To gain access to the expansion valve partially
lift the evaporator core from its position in the
cab floor.
4. Remove the screw securing the inlet and outlet
connections to the valve and pull valve from tub-
ing.
5. Replace the O-ring seals and lubricate with re-
frigerant oil prior to installing the valve using dis- F28714

assembly procedure in reverse.

6. Evacuate, leak test and recharge the system.
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48 SECTION 50 - CAB HEATING AND AIR CONDITIONING

EVAPORATOR
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Remove the seat and cover plate to reveal evap-
orator assembly (1).
3. Remove temperature cycling control thermocou-
ple.
4. Disconnect tubing to expansion valve.
5. Remove evaporator.
6. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
7. Clean the evaporator core of all foreign material
to be sure it is free of obstructions.
8. Check the evaporator assembly for indications
of refrigerant leakage. If damage or leaks are ev-
ident, replace the evaporator core.
If a new evaporator is to be installed drain the refrig-
erant oil in the evaporator into a clean calibrated
container. Measure the quantity of oil obtained and
add the same quantity of new refrigerant oil directly
into the replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.

AIR CONDITIONER TEMPERATURE CYCLING

CONTROL
1. Remove the seat mounting plate.
2. The temperature cycling switch (2) is mounted to
the side of the blower motor assembly.
3. Carefully pull and disconnect the switch wiring at
the connector.
4. Remove temperature control switch and replace
as required.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 49

LOW PRESSURE CUT-OUT SWITCH

1. With the engine “OFF” check continuity across
the switch contacts. If the switch (1) shows
“Open Circuit” replace as detailed below.

IMPORTANT: the pressure switch can not be re-

placed without discharging the system.

2. Remove switch by unscrewing from self sealing

Schrader valve.
3. Replace with new switch and connect to har-
ness.

BLOWER MOTOR ASSEMBLY

The blower motor (2) can if required be removed
without discharging the system as follows:
1. Remove the cab seat mounting plate.

NOTE: take care not to damage hoses during this

operation. If the cab heater hoses restrict movement
of the housing drain the heater assembly and dis-
connect the hoses.

2. Disconnect the motor wiring connector block.

3. Remove the remaining motor securing screws
and withdraw motor.
4. Re-assembly follows the disassembly procedure
in reverse.

RECEIVER DRYER
The receiver/dryer (3) cannot be overhauled and
must be replaced as an assembly. The receiver/dry-
er assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the sys-
tem has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using cer-
tified recovery systems.
2. Disconnect the hoses and switch and remove
the dryer from the tractor.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quan-
tity of new refrigerant oil directly into the new
item.
4. Cap and plug all fittings to prevent any dirt enter-
ing the system.
5. Install a new receiver dryer.
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50 SECTION 50 - CAB HEATING AND AIR CONDITIONING

CONDENSER
1. Remove the front grid. Unscrew and remove the
upper fixing nuts. Shift the filter sideways. Dis-
connect the connections to the condenser.
2. The removal of the attaching bolts allows the
condenser to be raised for cleaning. Remove
condenser from machine.
3. Inspect the condenser assembly fins for damage
and be sure they are not plugged.
4. Check the condenser for signs of leakage. If the
condenser is damaged or leaking, install a new
condenser assembly.
5. If the condenser is to be replaced, drain the re-
frigerant oil from the condenser into a clean cal-
ibrated container. Measure the quantity of oil
obtained and add the same quantity of new re-
frigerant oil directly into the new condenser.
6. Soak new tubing connector O-rings in clean re-
frigerant lubrication oil and install onto tubing.
7. Evacuate, leak test and recharge the system.
8. Install the grid.

CAB AIR FILTER

1. Before servicing the filters, switch off the blower
and close all windows and one door. Slam the fi-
nal door closed and the resulting back pressure
will dislodge most of the loose dirt from the un-
derside of the filters.
2. Remove filter element and clean by blowing with
compressed air not exceeding 2 bar.

IMPORTANT: make sure you protect your face be-

fore using compressed air.

Blow the dust from the upper surface through the

element to the underside. Hold the nozzle at
least 300 mm from the element to prevent dam-
age to the paper pleats.
3. Clean both filter chambers with a damp, lint free
cloth.
4. Replace the filter element with the rubber seal
uppermost and re-install the covers.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 51

3.9 COMPRESSOR

TECHNICAL SPECIFICATIONS

Basic compressor specifications

Displacement ............................................................................................................................................ 155 cc
Weight........................................................................................................................................................9.9 kg
Oil type........................................................................................................................................................SP20
Rotation.............................................................................................................................. CW (Clockwise only)
Compressor clutch and pulley air gap............................................................................................... 0.9-0.8 mm

Belt tension
Measure at the widest gap.................... 10 mm deflection with 1 kg force applied midway between the pulleys

Speed rating

MAXIMUM RPM
Constant Downshift
6000 8000

Tightening torques

COMPONENT Nm
Armature retaining nut, M8 17.7±2.9
Cylinder head bolts, M6 13.7±2.9
Cylinder head bolts, M8 34.3±4.9
Clutch dust cover screw, M5 9±2
Oil filler plug 19.6±4.9

52 SECTION 50 - CAB HEATING AND AIR CONDITIONING
FAULT FINDING
During diagnosis follow the inspections procedures in the sequence shown until a default is found. Then per-
form the repair in the “Cause and Remedy” section. If this repair does not fully solve the problem, proceed to
the next inspection step.
PROBLEM
Unusually high suction
pressure with unusually low
discharge pressure
Unusually low suction and
discharge pressure
Intermittent or inoperative
Rough running
PROBLEM
Clutch engaged
Clutch disengaged
“chattering”
Copyright ©
CAUSE ACTION
Valve plate test Replace or repair:
Broken head or block gasket.
Broken or deformed reed valve.
Foreign substance under reed valve
or gasket.
Check for low refrigerant charge Replace or repair:
Shaft seal leak.
Leak check compressor Cylinder head leak.
Gasket leak.
Leak check and diagnose system Oil filler plug leak.
Cracked cylinder block.
Front housing O-ring leak.
Check belt tension Replace.
Check clutch air gap Adjust air gap.
Check clutch volts, amps, coil lead Replace or repair:
wire Broken lead wire.
Clutch coil defect - Internal.
System ground (see system
manual).
Shaft turning smoothness test Compressor failure - Internal.
CAUSE ACTION
Check compressor mounting Replace or repair.
components
Check engine components Replace or repair.
Check for intermittent or slipping Adjust air gap - defective coil.
clutch
Check for proper refrigerant charge Recharge and recheck.
Check clutch bearing Replace rotor / Armature assembly.
Oil level procedure Restore to proper level.
Shaft turning smoothness test Compressor failure (Internal).
Remove valve plate and inspect Replace or repair:
Broken discharge valve reed or
retainer.
Broken suction valve reed.
Broken gasket.
Check air gap Replace or repair:
Adjust air gap.
Defective clutch pulley or front plate.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 53

REMOVAL AND INSTALLATION

13

10
7

12

11 1
7 2
5
8

14

9
1 3 6 5
F28721

Removal
Discharge the air conditioning system. Disconnect
the electrical harness of the compressor (12) from
the electrical harness of the engine. Disconnect tub-
ing to compressor. Remove the washer (7) and the
screw (1). Remove the protective guard (13). Re-
move the bolt (11). Remove the nut (14) and the
screw (9).
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54 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Remove washers (5), nut (6), screw (2) and the

block (8). Remove screw (1), washers (3) and the
belt tensioner (4). Remove the screw (10), the
washers (2) and the compressor (12).

Installation
Installation is the reversal of the removal but the fol-
lowing points should be noted:
Z Torque the fixing bolts to 40-51 Nm.

NOTE: it is recommended that a new receiver/drier

assembly is installed after any system component
replacement or any repair that requires entry into
the system.

Z Drain the oil from the new compressor to be fitted

into a clean container, or if the old compressor is to
be refitted, obtain a new can of refrigerant oil.
Z Calculate the amount of oil to be installed and refill F28723

the compressor.
Z Reconnect the hoses to the compressor and tight-
en all bolts and hoses.

After charging a system use the following start up

procedure to ensure the lubricating oil is properly
dispersed around the system:
Z Ensure air conditioning is switched “OFF”.
Z Start the engine and bring speed down to idle.
Z Turn the air conditioning “ON” and allow system to
operate for at least five minutes before increasing
engine speed.

A correctly tensioned belt can be deflected 13-19

mm when hand pressure is applied midway be-
tween the alternator and crankshaft pulley.
Once adjusted re-torque the tension arm bolt to 33.9
Nm.

F28725
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 55

The compressor drive belt (1) can be tensioned by

rotation of the idler arm (2). Slacken the idler arm
bolt and adjust the arm to a belt deflection of 16 mm.
Once adjusted re-torque the tension arm bolt to 33.9
Nm.

F28726

OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Z Remove the oil plug and drain as much oil as pos-
sible into a suitable container.
Z Remove the caps (if present) from suction and dis-
charge ports.
Z Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retain-
CC
ing nut.

F28727

Z Measure and record the amount of oil discharged.

Z Inspect the oil for signs of contamination such as
discoloration of foreign material.

F28728
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56 SECTION 50 - CAB HEATING AND AIR CONDITIONING

CLUTCH

1 2 3 4 5 6 7 8 9 10

F28729

1. Cover screw 6. Cover

2. Dust cover 7. Snap ring
3. Nut 8. Rotor assembly
4. Plate 9. Snap ring
5. Shims 10. Field coil

Disassembly
All clutch servicing should be done with the com-
pressor removed from the vehicle. Support the com-
pressor. If using a vice, do not hold on to the
housing. If dust cover (2) is present, remove the 3 or
6 bolts (1) holding it in place and remove cover. If
auxiliary sheet metal pulley is present, remove the
screws holding it in place. Then remove pulley. 4
Attach tool to the cover on the front of the clutch
plate and placing a socket and ratchet through the
tool remove the cover attaching nut (3).

F28730

Using the front plate tool and a tommy bar hold the
clutch plate stationary.
Place the bolt into the tool and by tightening the bolt
onto the end of the shaft the front plate will be ex-
tracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove dust cover (6) (if present). Use caution to
prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. Remove shims (5). Use a F28731

pointed tool and a small screwdriver to prevent the

shims from binding on the shaft.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 57

Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.

F28732

Inspect the rotor assembly (8) for wear and replace

the assembly as necessary.
8

F28733

Remove the field coil wire retaining clip.

F28734

Remove the field coil snap ring (9).

F28735
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58 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Lift the coil (10) from the housing and replace as re-
quired. 10

F28736

Assembly
Install the field coil (10), ensuring that the wire is lo-
cated back at cable clip on the outside of the body
and snap ring (9) is placed in the groove. 10

F28737

Position the rotor (8) on the housing hub and care-

fully slide the rotor (8) down the shaft.

F28738

Install the snap ring (7).

F28732
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 59

Replace the plate (4) and retaining nut and tighten

to a torque of 18 Nm.

F28730

Check the clearance between the plate (4) and rotor

(8). This should be consistent around the circumfer-
ence and be between 0.4-0.8 mm. 4

NOTE: if the air gap is not consistent, lightly pry up

on the counter weighted front plate at the low spots
or lightly tap down at the high spots.

8
F28741

If the clearance is not within specification the shims

(5) under the front plate should be added to or sub-
5
tracted from, until the correct clearance is obtained.

NOTE: new shims are available in sizes 1.00, 0.50

and 0.13 mm.

Replace dust cover (2) if present and torque 3 on 6

bolts (1) as specified into Tightening torques.

F28742
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60 SECTION 50 - CAB HEATING AND AIR CONDITIONING

COMPRESSOR

5 6 7 8 9 10

1 3

2 4

F28743

Air conditioning refrigerant compressor

1. Shaft key 6. Gasket
2. Ring 7. Plate
3. Shaft seal snap ring 8. Head gasket
4. Lip seal with O-ring 9. Cylinder head
5. Oil plug 10. Cylinder head bolt

Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Z Remove the armature plate, as detailed in the
steps of clutch disassembly.
Z Remove the shaft key (1), shims and ring (2) to ex-
pose the snap ring (3). 3
Z Remove the snap ring (3).

F28744

Insert the seal remover/installer tool (A).

Twist the tool to engage the slots in the seal. Pull up
to remove and discard the seal (4). A

F28745
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 61

Installation
Thoroughly clean the seal cavity in the hub. Use “lint
free” cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly. Dip the new seal assembly in
clean refrigerant oil and attach to the seal remover/
installer tool.

F28746

Insert the new seal fully into the hub.

NOTE: if remover/installer tool (B) is not available, B

position the seal squarely in the hub and tap gently
until fully seated.

F28719

Install the snap ring (3). If the snap ring has a bevel-
led edge this should face outwards.

F28744

Install a new ring (2) and push into position.

F28713
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62 SECTION 50 - CAB HEATING AND AIR CONDITIONING

Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassem-
bly.

F28911
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 63

CYLINDER HEAD

Disassembly
Drain the refrigerant oil from the compressor into a
clean calibrated container. Measure and record the 10 9
quantity of oil obtained. This information is required
during installation of the new or overhauled unit.
Remove the six cylinder head bolts (10) and using a
hide mallet, gently tap the cylinder head (9) free.
The use of a gasket scraper may also be required to
free the cylinder head from the compressor body.

F28747

If the plate (7) and/or cylinder head are to be reused,

carefully remove the gasket (8) using a suitable 7
scraper.

F28748

Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage. 7

F28749

Reassembly
Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the re-
verse of the disassembly procedure.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head bolts and tighten using the
sequence shown. Torque initially to 20 Nm.
When the overhaul is complete add to the compres-
sor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.

F28750
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64 SECTION 50 - CAB HEATING AND AIR CONDITIONING

OIL RETAINED IN SYSTEM COMPONENTS

After replacement of individual system components it
will be necessary to add some oil to the system to
make up the amount lost in the removed component.
The table below shows some typical volumes for the
components. It is, however, still recommended that
the oil level measurement, described previously is
carried out after a new component has been installed
to establish correct oil quantity.

Typical oil amount

Component
fl.oz. cc
Accumulator 2.0 60
Evaporator 2.0 60
Condenser 1.0 30
Receiver/drier 0.5 15
Hoses 0.3 10

Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 volt battery check current drawn by
the field coil which should be between 3.6-4.2
Amps.
Very high current readings indicate a short cir-
cuit in the field coil and no current reading indi-
cate an open circuit. Replace coil with either
fault. Resistance of the coil using an ohmmeter F28751

should be approximately 3.0 Ω at 20 °C.

A poor ground connection of the field coil will re-
sult in a low voltage.
3. Ensure clutch is disengaged and rotate pulley by
hand. If roughness in the bearing is felt, it will be
necessary to replace the pulley and bearing as
an assembly.

F28752
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SECTION 50 - CAB HEATING AND AIR CONDITIONING 65

3.10 SPECIAL TOOLS

Only certified refrigerant recovery, recycling and recharge equipment suitable for the type of refrigerant gas
HFC 134a should be used on these vehicles when servicing the air conditioning system.
This special equipment is available through recognized suppliers of air conditioning equipment. Refer to the
“Tool supplier” for details on the latest equipment available for servicing the air conditioning system.

P/N DESCRIPTION USE

380000315 Recovery / recharge portable system Discharging and recovering of the
refrigerant
380000312 Evaporator and condenser cleaner Evaporator and condenser cleaning
380000314 Electronic gas leak detector Leak testing
 Copyright ©

66 SECTION 50 - CAB HEATING AND AIR CONDITIONING

NOTE:
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 25
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 45
2.4 ELECTRICAL DIAGRAMS - ROPS ..................................................................................................... 65
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 81
3.1 FRONT INSTRUMENT PANEL (580 Super R - 590 Super R) ............................................................ 81
3.2 SIDE INSTRUMENT PANEL (695 Super R)........................................................................................ 83
3.3 SIDE PANEL........................................................................................................................................ 85
3.4 DIAGNOSTIC SIGNALING .................................................................................................................. 88
3.5 CALIBRATION OF SPEEDOMETER .................................................................................................. 90
3.6 IMMOBILISER CIRCUIT...................................................................................................................... 91
4. STARTING SYSTEM .................................................................................................................................. 92
4.1 DESCRIPTION AND OPERATION...................................................................................................... 92
4.2 FAULT FINDING.................................................................................................................................. 93
4.3 STARTER MOTOR.............................................................................................................................. 96
5. ALTERNATOR.......................................................................................................................................... 102
5.1 TECHNICAL SPECIFICATIONS........................................................................................................ 102
5.2 DESCRIPTION AND OPERATION.................................................................................................... 102
5.3 COMPONENTS ................................................................................................................................. 104
5.4 REMOVAL ......................................................................................................................................... 105
5.5 PRELIMINARY CHECK AND TESTS................................................................................................ 106
5.6 FAULT FINDING................................................................................................................................ 115
 Copyright ©

2 SECTION 55 - ELECTRICAL SYSTEM

6. BATTERY.................................................................................................................................................. 116
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 116
6.2 DESCRIPTION AND OPERATION.................................................................................................... 116
6.3 BATTERY REPLACEMENT............................................................................................................... 117
6.4 MAINTENANCE ................................................................................................................................. 119
6.5 TESTS................................................................................................................................................ 121
6.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 123
6.7 BATTERY MASTER SWITCH ........................................................................................................... 123
7. COMPONENT TESTING .......................................................................................................................... 124
7.1 GENERAL INTRODUCTION ............................................................................................................. 124
7.2 COMPONENT TESTING ................................................................................................................... 125
7.3 GROUND POINTS............................................................................................................................. 125
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 3

1. GENERALITIES
1.1 TEMPORARY WIRING HARNESS REPAIR

The following method to repair wiring is a temporary

expedient only. Wiring should be replaced as soon
as possible. Replacement of temporary repaired ca-
bles with new is particularly important if the tractor is
to be used for spraying as chemicals can enter the
repaired area, travel up the cable and damage elec-
trical components. Do not attempt to repair the wire
on any system sensors as these are sealed and
should only be replaced with a new component.

NOTE: when conducting a cable repair it is impor-

tant that only RESIN CORED SOLDER is used. Use
of other types of solder ma result in further cable
damage.

To carry out a temporary repair, proceed as follows:

Z Locate damaged portion of cable then cut away
outer protective cover on both sides of the dam-
aged area.
Z Peel back the cable from both ends of the dam-
aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13 mm
(1/2 inch) of insulation from the wires. Do not cut
away any wire strands.
Z Using a suitable solvent, clean about 2 inches (50
mm) from each cover end. Clean the grey cable
cover and the individual leads.

Z Twist two bare leads together for each damaged

lead, being careful to match wire colours, then sol-
der the leads using resin cored solder. Tape each
repaired lead with vinyl insulation tape.
Z Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section. Make
a paper trough, then apply silicon rubber com-
pound (non hardening sealant) over the repaired
section up to the cover ends. Sufficient sealant
must be used to fill the ends of the cut away area.

Z Allow the compound to cure then cover the area

with insulating tape taking the tape well over each
end of the repair. An overlap of at least 2 inches (50
mm) of tape at each end is necessary.
Z Check to ensure the repair is satisfactory and se-
cure the repaired cable so that repeat damage is
avoided.

NOTE: this is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
 Copyright ©

4 SECTION 55 - ELECTRICAL SYSTEM

1.2 FAULT FINDING

PROBLEM CAUSE ACTION

Electrical system is inoperative Loose or corroded battery Check battery open circuit voltage
connections for 12.6 volts minimum.

Clean and tighten connections Check electrolyte level and specific

Sulphated batteries gravity.

Battery Isolator switch turned Re-instate isolator switch.

“off”

Main machine fuse link blown Establish reason of failure and

replace fuse link.
Starter speed low and engine Loose or corroded connections Clean and tighten loose
cranks slowly connections.

Low battery output Check battery open circuit voltage

for 12.6 volts minimum.
Check electrolyte level and specific
gravity.

Incorrect viscosity engine oil Use correct viscosity oil for

temperature conditions.
Starter inoperative Transmission shift lever in gear Place shift lever in neutral.

Loose or corroded connections Clean and tighten loose

connections.

Dead batteries Charge or replace batteries.

Charge indicator lamp stays on Low engine idle speed Increase idle speed.
with engine running
Loose belt Check belt tension.

Malfunctioning battery Check battery open circuit voltage

for 12.6 volts minimum.
Check electrolyte level and specific
gravity.

Malfunctioning alternator Check alternator.

Batteries will not charge Loose or corroded terminal Clean and tighten connections.
connections

Sulphated batteries Check battery open circuit voltage

for 12.6 volts minimum.
Check electrolyte level and specific
gravity.

Loose or worn belt Check automatic belt tensioner.

Replace belt if required.
Charge indicator flashing Malfunctioning alternator Check alternator.
indicating excessive charging
voltage
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 5

2. ELECTRICAL DIAGRAMS
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB

FUSES AND RELAYS DESCRIPTION

NAME DESCRIPTION
F1A Rear windshield wiper and rear windshield washer (15 A) K12

C1
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A) K10 K11
F1C Stop lights switch (10 A)
K1

11
6

7
BZ1

XC2
Instruments power supply, brake oil level sensor, seat,

XC1
F2A
buzzer (15 A)

D1

D5
D3
1

5
F2B Conditioner (15 A) K2
F1/C F2/C

7
D6

F2C Pilot control (15 A)

D4

21
11
F1/B F2/B

1
Rear right/front left side lights, instruments illumination,

8
F3A
conditioner switch illumination (3 A)

XC6
D2
F1/A F2/A

XC3
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, tools rapid connection, Glide Ride F3/C F4/C
F3C

13

7
control, double delivery switches (10 A)
F3/B F4/B K3
Forward speed, reverse speed, reverse buzzer, speed
F4A

12
1
switch (5 A) F3/A F4/A
K4

21
11
Rear hammer button, grab level valve and sensor,
F4B
clutch shut off buttons (10 A)

17
9
Rear excavator lock, rear translation lock, rear work F5/C K5
F4C XC4
light (10 A)

XC5
F5A Front inner work lights (15 A) F5/B
K6
F5B Traffic lights (10 A) F5/A
12
1

10
1

F5C Main beam fuse (15 A) K7

F6/C F7/C F8/C
F6A Beacon lamp (7.5 A)
K8
F6B (+15) Flasher (7.5 A) F6/B F7/B F8/B
F6C Hand hammer, 4WD (7.5 A) F6/A F7/A F8/A K9
F7A (+30) Flasher, (+30) Antitheft, horn (10 A)
GND
1B020411
+15V

+30V

F7B Current intake, radio, roof lamp (10 A)

J1

J3

F7C Front windshield wiper (6 A)

J2

F27167
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
 Copyright ©

6 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Forward-reverse speed switch relay
K12

C1
K2 Speed alarm, hand brake relay
K10 K11
K3 Starting relay
K1

11
6

7
K4 Grab level solenoid valve relay BZ1

XC2
XC1
K5 Traffic and main beam lights relay

D1

D5
D3
1

5
K2
K6 Inner front work lights relay
F1/C F2/C

7
D6
D4
K7 Inner rear work lights relay

21
11
F1/B F2/B

1
8
K8 Outer front work lights relay

XC6
D2
K9 Outer rear work lights relay F1/A F2/A

XC3
K10 Reverse speed relay
F3/C F4/C
K11 Forward speed relay

13

7
K12 Flasher F3/B F4/B K3

12
1
F3/A F4/A
K4

21
11

17
9
F5/C K5

XC4

XC5
F5/B
K6
12 F5/A
1

10
1 K7
F6/C F7/C F8/C
K8
F6/B F7/B F8/B

F6/A F7/A F8/A K9

GND
1B020411
+15V

+30V
J1

J3
J2

F27167
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 7

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION

BS1 Right speaker (optional) M7 Front windshield washer
BS2 Left speaker (optional) M8 Blower motor
BZ1 Alarm buzzer M9 Optional blower motor
EV1 Double delivery solenoid valve (optional) M10 A/C compressor
EV2 Hand hammer solenoid valve (optional) R2 Engine water temperature sender
EV3 Rear hammer solenoid valve (optional) R3 Fuel level sender
EV4 Rear translation solenoid valve R4 Transmission oil temperature sender
EV5 Excavator rear lock solenoid valve (optional) S2 4WD switch (optional)
EV6 Grab level solenoid valve S3 Hand hammer switch (optional)
EV7 Fuel shut off solenoid valve S4 Double delivery switch (optional)
EV8 4WD solenoid valve (optional) S5 Ride control switch (optional)
EV9 Reverse speed solenoid valve S6 Tools switch (optional)
EV10 Forward speed solenoid valve S7 Rear translation lock switch
EV11 Ride control solenoid valve (optional) S8 Excavator rear lock switch (optional)
EV12 Tools solenoid valves (optional) S9 Lights switch
FG1 General fuse 80 A S11 Front work light switch
FG2 A/C fuse 10 A S12 Rear work light switch
G1 Battery S15 Beacon lamp switch
G2 Generator S17 Starting switch
H1 Excavator rear lock warning light (optional) S18 Handbrake switch
H2 Front left light S20 Engine oil low pressure switch
H3 Front right light S21 Air filter blocked switch
H4 Rear left light S24 Transmission oil pressure switch
H5 Number plate lamp S26 Clutch shut off button
H6 Rear right light S27 Clutch shut off button
H11 Outer front left work light S28 Grab sender
H12 Outer front right work light S30 Rear hammer pedal button (optional)
H13 Outer rear left work light S31 Brake oil level sender
H14 Outer rear right work light S32 Stop light switch
H15 Beacon lamp S33 Stop light switch
H16 Beacon lamp S34 Roof lamp left switch
H17 Current intake illumination S35 Roof lamp right switch
H18 Cab lamp S40 Gear shift
H19 Inner front left work light (optional) S41 Windshield wiper - Lights switch
H20 Inner front right work light (optional) S42 Hazard
H21 Inner rear left work light (optional) S43 Radio (optional)
H22 Inner rear right work light (optional) S44 Seat (optional)
HA1 Reverse speed buzzer S45 Conditioner and blower motor switch
HA2 Horn S46 Current intake
HA3 Optional buzzer S47 Main switch
K01 Starter relay S48 Cold start temperature switch
K02 A/C relay S49 Air conditioned pressure switch
K13 Antitheft unit S52 Solenoid valves lock switch (optional)
KC Fuses-relays board S53 Rear washer button-wiper switch
M1 Starter motor S54 Rear horn button (optional)
M4 Rear windshield wiper motor ST2 Side multifunction panel
M5 Front windshield wiper motor General cable-engine cable 18 way
X1
M6 Rear windshield washer connector
 Copyright ©

8 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION

X2 Cold start 6 way connector Rear left light predisposition 4 way
X48
X3 Fuel shut off 1 way connector connector
X4 Air filter 2 way connector X49 Front windshield wiper 6 way connector
X6 Forward speed 2 way connector Front left work light (optional) 4 way
X50
X7 Reverse speed 2 way connector connector
General cable-rear lamps cable 12 way X51 Front left work light 4 way connector
X8 Front left indicator predisposition 4 way
connector X52
Solenoid valves cable - general cable 29 connector
X10 X53 Radio (brown colour) 8 way connector
way connector
X12 General cable-cabin cable 5 way connector X54 Radio (black colour) 8 way connector
X14 Antitheft 11 way connector X55 Current intake 2 way connector
X15 Start switch 10 way connector X56 Front windshield washer 2 way connector
X16 Optional 1 way connector X57 Rear windshield washer 2 way connector
X17 Seat 4 way connector X61 Wiper and lights switch 12 way connector
X21 Horn/left light 7 way connector X62 Gear shift 6 way connector
X22 Right light 5 way connector X63 Number plate light 2 way connector
X23 Clutch shut off button 2 way connector X64 A/C compressor 1 way connector
Rear translation lock solenoid valve 2 way X67 Generator 3 way connector
X24
connector Engine water temperature sender 3 way
X68
Excavator rear lock solenoid valve 2 way connector
X25
connector X69 A/C pressure switch 2 way connector
X26 Grab sender 3 way connector X70 Front panel 12 way connector
X27 Pilot control horn button 2 way connector X71 Starting switch 10 way connector
X28 Clutch shut off button 2 way connector X72 Pilot control line 1 way connector
X29 Grab level 2 way connector Engine oil pressure switch 1 way
X73
Double delivery solenoid valve 2 way connector
X30
connector X80 Beacon lamp 2 way connector
Tools rapid connection solenoid valve 2 way X81 Beacon lamp 2 way connector
X31
connector X82 Controller 10 way connector
Rear hammer solenoid valve 2 way X83 Relay 2 way connector
X32
connector Left side dashboard cable - generator cable
X34 Ride control solenoid valve 2 way connector X87
13 way connector
Hand hammer solenoid valve 2 way Right side dashboard cable - generator
X35 X88
connector cable 9 way connector
X36 Rear hammer button 2 way connector X89 Left lights 6 way connector
Rear right light predisposition 4 way X101 Right lights 6 way connector
X37
connector Solenoid valve lock switch kit 1 way
X38 Rear right work light 4 way connector X104
connector
X39 Rear windshield wiper 4 way connector X110 Conditioner 2 way connector
Rear right work light (optional) 4 way X111 Conditioner 9 way connector
X40
connector X124 Lifting solenoid valve 2 way connector
X41 Optional blower motor 2 way connector X125 Lifting solenoid valve 2 way connector
Front right indicator predisposition 4 way XA Horn 2 way connector
X42
connector
XC1 On board 11 way connector
X43 Beacon lamp 4 way connector
XC2 On board 7 way connector
X44 Front right work light 4 way connector
XC3 On board 21 way connector
Front right work light (optional) 4 way
X45 XC4 On board 21 way connector
connector
XC5 On board 17 way connector
Rear left work light (optional) 4 way
X46 XC6 On board 13 way connector
connector
X47 Rear left work light 4 way connector XD Fuel shut off diode 2 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 9

NAME DESCRIPTION
XD1 Handbrake switch diode 2 way connector
XST2 Side multifunction panel 36 way connector
 Copyright ©

10 SECTION 55 - ELECTRICAL SYSTEM

ENGINE LINE

ST2
58 15/54 50
P0 12 15.5
25 18.6
30
12.4
20 21.7 MPH
35 km/h

S17
9.3
30 15
1 2
n/min
6.2
10
4

15.5/XXXLS

x1 000
0 3

5 6 2 8 1
X15 X15 X15 X15 X15 1 2 3 4 5 10 12 15 17 19 20 21 22 24 25 31 35 36
XST2

M1
G1
B1

S1

V1

G-R1

R-G1
Z1
R-N1

B-G1

G-V1

G/N1

C-N1
S-N1
B-V1

V-N1

Z-B1
C-N1 7.3
R-N1 8.1

B-V1 4.1
1 2 G/N1
XD1 XD1 8.2
G/R1

G/R1
16 7 S18
X13 X13

V1
H/R1 4.1
V1 4.1
G-R1 4.2
A2.5 5 2
A2.5 XC6 XC6

A2.5
+15
3
R6 2.5

+30

L-N1 2.1

1 2.3

K3 86 87a 87
2 4.3
H/R1
L-N1

B-N1.5
B-N1.5

L-N1.5

85 30

+15

1 2 3 4 5 6 7 8 9 10 11 F1B F2C
X14 7,5A 15A
N1.5

N1.5

K13

KC
6 13 3 10 9 7
XC6 XC6 XC6 XC6 XC6 XC6
H2.5
A2.5

G-V1.5 8.4
M1
R10

S1

B1

B-G1
S-N1
B/N1

L1.5

8
X1
1 11 13 12 9 16 7 GRID HEATER 1 10 15 2 14 5 3
G-V1.5

X1 X1 X1 X1 X1 X1 X1 X10 X1 X1 X1 X1 X1 X1
TO COLD
START KIT
R10

L-N1.5

B1

G-R1
Z1
B-G1
B-N1

V/N1

Z-B1
H2.5

B-N1
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
K01 K02 1
86 87 86 87
X72

TO PILOT
85 30 85 30
CONTROL LINE
R2.5
V2.5
R4
R2.5

l
XD
V-N1

FG1 FG2
80A 10A
S1
S-N1

R16 -
V-B1

XD
L-N1
R25

R70 2 1 3
X67 X67 X67
G1 A B
B4

1 X68 X68
X64 1 1 A
12Vcc M1 2 M10 X3 X73 X4
30 50
S49
X69 G2 D+ EV7 S48 S20 S21
R2 R3
S24
R4
M M 30 G W
p 3 t p p p
N70

U
t t
S47 1 31
X69 B
C X4
N2.5

N1.5

X68
N1

N1

N1

N1

N1

N1

N1
N1
N70

31 2.1

F27479
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 11

SOLENOID VALVES SCHEMATIC

1 3 4 2 4 I II F N R NO
CB A A B I II F
0
R
S2 M-V1
2
S3 3
S40 + + NI
R-N1

1 2 3 4 5 6
N1 X19

M-B1
L/G1
C1 4.4
N1 4.3
R-N1 5.1

G/R1 7.1

10
X13

C1
M-N1
M-B1
M/B1

G/R1

H-N1

L/G1

7 2 6 11 5 9 3 1
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1

1.4
3
F6C
7,5A
+15 +15

+15
F4B F4A
10A 5A

1.4
1

K1 86 87a 87
K4 86 87a 87
K10 86 87a 87
K11 86 87a 87
K2 86 87a 87

85 30 85 30 85 30 85 30 85 30

KC
5 1 6 9 19 16 8 8 1 11
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6 XC3
L-N1

C1
1.1
L-N1 7.1
R-V1 R-V1 3.5
M-V1

C1
M-N1
M-B1
H-N1

A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

18 6 7 8 24 9 11 29 14 10 4 17 20
X1 X1 X10 X10 X10 X10 X10 X10 X10 X10 X1 X1 X10
M-B1

M-B1
H-N1

A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

M-N1
M-V1

C-N1
M-B1

M-B1
A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

2 1 1 2 1 2 1 2 C A B 1 2 1 2 2 1 2 2 1
X8 X8 X35 X35 X28 X28 X23 X23 X26 X26 X26 X29 X29 X7 X7 X19 X6 X6 X27 X27
EV2
EV8 S26 S27 S28 EV6 EV9 HA1 EV10 TO PILOT
1

CONTROL HORN
2

1
N2.5

N2.5

X19
N1

N1

N1
N1

N1

N1

N1

N1

1.5
31 31 3.1

F27480
 Copyright ©

12 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVES SCHEMATIC

C/B1 C/B1 6.2

C/N1
A B
2 4
A B
2 4
B A
1 3 4
A B
3 1 6 4
A B
2 4
B A
1 3
H1

S4 3
S5 3
S6 2 S52 2 5
S7 3
S8 2 4

N1
C/N1
A-N1

B-N1
L-G1

C/N1
N1

N1 7.1
N1
C/N1 7.5
4.1

L/G1
C/N1

C-B1
C/B1
V/B1

6 3 2 1 7 9 9 10
X13 X13 X13 X104 X88 X87 X88 X87
V1
A-N1

B-N1

C-B1
L-G1

L/G1
C/B1 6.1

N1 7.1
M1

M1

2.5
R-V1
R-V1

23 16 27 18 17 15
X10 X10 X10 X10 X10 X10
R-V1

2
X36

S30
V1
A-N1

B-N1

C-B1
L-G1

1
X36
R-V1

1 2 1 2 2 1 1 2 1 2 1 2 1 2 1 2
X30 X30 X34 X34 X31 X31 X124 X124 X125 X125 X24 X24 X25 X25 X32 X32
EV5 EV3
EV1 EV12 EV24 EV25 EV4
EV11
1

1
N1

2
N1

N1

N1

N1

2.5
31 31 4.1

F27481
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 13

LIGHTS SCHEMATIC

3.5
N1 N1 6.1

1.4
G-R1

H/R1

G1.5
15/1 30/3 R/7 4 6 1 3
0 1 C BA

G-R1
S42 49/4 30b/2 49a/5 L/6
S9 5 2

H-L1
S31

A1
L1

H-N1.5

R2.5

R1.5
L-N1 7.1
A1 7.1
L1 7.1

6 5 4 3
X87 X87 X87 X87

1.1
H/R1 V-N1.5 7.1

1.5
B-V1
1.3
V1

12 14 8 13 11 4 15
X13 X13 X13 X13 X13 X13 X13

H-N1.5
V-N1.5
G-N1

H-R1

R/N1

H/R1
B-V1
G1.5

H-L1

L-N1

R2.5

R1.5
H1

3 18 6 21 10 10 9 3 8 16 20 5 4 2 4 13 2
XC2 XC4 XC4 XC4 XC1 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC1 XC4 XC5

+15 +30 +15

F6B F5B F5C F2A F7A
11 5.1 7,5A 10A 15A 15A 10A L1 5.1
10 5.1
A1 5.1
+15 +30

K12
F3B F3A + K5 86 87a 87
3A 3A L C
51 8.3
85 30
-

BZ1

KC 2 50
1.4 7.5
10
XC3

2.5
N1

2.5
C1
C1

H1

A1
H-N1
L1
H/R1

V-N1

6 7 1 4 5 2 3 1 4 5 2 3
X21 X22
G1
C1

N1
H1

H1
V1

V1
A1
G-N1
L1
H/R1

1 2
XA XA
C1

H-R1

1 2 3 5 4 1 2 3 5 4
X89 X89 X89 X89 X89 X101 X101 X101 X101 X101

H2 H3
HA2
R
L
56b

56a

58

56b

56a

58
31

31

3.5
31 31 5.1

F27482
 Copyright ©

14 SECTION 55 - ELECTRICAL SYSTEM

REAR LIGHTS SCHEMATIC

2.5
R-N1

S32 S33

4.5
L1

4.5
A1
R1
G1
A1

A1
G-N1

R-N1
R-N1
L1
L1

B/R1
19 17 7 8 9 6 8 2 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC1 XC1 XC5

F1C
10A

+15

4.2
11

4.2
10 52 8.3

KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1

R-N1
L1

G1 8.3
G1
A1
G-N1

G-N1
R-N1

R-N1
L1

G1
N1

N1

N1

N1
A1

A1
G-N1
R-N1

R-N1
L1

L1

5 2 6 4 3 9 8 10 7 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X8 X52 X48 X42 X37
G1
N1

N1

N1
A1
G-N1

G-N1
R-N1

R-N1
L1

N1
G-N1

2 1
X63 X63
H4 H6
H5
59c

59c
R
L

58

58
31

31

N1

N1

4.5
31 31 6.1

F27483
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 15

WORK LIGHTS SCHEMATIC

C/N1 C/N1 7.1

3.5
C/B1

2 4 2 4
A B A B

S11 3
S12 3

4.5
N1 N1 N1 7.1
S-G1

Z-N1

C/B1
1 11 7
X87 X87 X87
S-G1

Z-N1

C/B1
S-G1

Z-N1

3 14 4 12 14 13 15 11 18
XC3 XC5 XC3 XC5 XC3 XC5 XC3 XC5 XC3

F4C
+30 +30 +30 +30 10A
H1
V1

H-N1

V-N1
F5A F8B F8C F8A +15
15A 15A 15A 15A

K6 86 87a 87
K8 86 87a 87
K7 86 87a 87
K9 86 87a 87

85 30 85 30 85 30 85 30

KC

3.5
C/B1
N1

H1

N1

H1

N1

N1
V1

H-N1

H-N1

V-N1

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X51 X50 X44 X45 X47 X46 X38 X40

H11 H19 H12 H20 H13 H21 H14 H22

5.5
31 31 7.1

F27484
 Copyright ©

16 SECTION 55 - ELECTRICAL SYSTEM

WINDSHIELD WIPER WASHER SCHEMATIC

R-N1 8.1
6.5
C/N1

3.2
C/N1
N1

S53 57/58 56b 56a 54S 54D 53 31b 49

H15 H16
0 12 R
5 3 1 6 4 9 0 2 4
A B 2 1 0 A B M M
L
S41 56 30 L 15 31

S54 6 2 5 7
S15 3
C1

A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X61 X80 X80 X81 X81

V-N1.5

A1
G/R1

L1
A/N1
A/R1
A/B1

L-N1
3.5
N1
N1

M1
3.5

L1
4.5
A1
L-N1 HA3
4.5 1 2 3 4
L1

A-G1.5
4.5 X43
2.2
G/R1
4.5
V-N1.5

C-N1
N1

C/N1
6.5
N1

C/N1
A/N1

A/R1

A/B1

L-B1
L/B1

12 6 5 1 2 4 3 9 1.5
C-N1 5 1 2
X87 X88 X88 X88 X88 X88 X88 X13 X13 X13 X87
C1

C-N1

C/N1
C/N1
A-G1.5

A-G1.5
A-V1.5

Z1
Z1
R/N1

A/B1
N1

4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3

2.5
C1

F7C
6A A.R. F6A F3C
7,5A 10A

+15 +15 +15

+15

F1A
15A

4.4
50
KC
17
XC3
A/N1
A/R1

A/B1

L-B1
L/B1

5 6 5 4 1 2 3
X10 X10 X12 X12 X12 X12 X12
R/N1
A/N1

A/N1
A/R1

A/N1
A/B1

A/B1
L-B1
L/B1

- l 4 1 2 3 - l - l 6 3 4 1
X41 X41 X39 X57 X57 X56 X56 X49
M4 M6 M7 M5
M9 53a 53a
53 M
53b M M 53 M53b
31b 31b

31 31
N1.5
N1.5
N1.5

N1
N1

N1

N1

N1
N1

6.5
31 31 8.1

F27485
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 17

HEATER AND RADIO SCHEMATIC

5.5
G1
BS2 OFF
0

G1
S43 ON
S46 H17 1 2 3 4 5 6 7 8 9 10 11
S45
H18
BS1

H1
B1
V1
S1
A1
G1.5
R1.5
C1.5
Z2.5

G-V1.5
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
X53 X54 l -
X55 X55

R-N1

N0.5
R0.5
N0.5
R0.5

N1

M-N1
B/R1
R-N1

N1
G-V1.5
1.1

R-N1

N1
1.5
R-N1
R-N1

7.5

N4
X14

G/N1 S34 S35

1.5
4
R-N1.5

X14

G/N1

R-N1.5

Z2.5

R4
1 2 1 2 3 4 5 6 7 8 9
11 12 10 4 X110 X111
XC6 XC6 XC5 XC6
R-N1
N1

1 2 3 4
X17

S44 F7B F2B

10A 15A

+30 +15

4.4
51

5.2
52
+30

KC
N1.5

7.5
31

F27486
 Copyright ©

18 SECTION 55 - ELECTRICAL SYSTEM

COLD START SCHEMATIC

CONTROLLER

1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82

G1
R1

N1

M1

N1
S1
B-N1

V-B1
L-N1

1 2
X83 X83

1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER

RELAY
TO ENGINE LINE

F27176
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 19

SIDE INSTRUMENT

Functional description

PIN NAME FUNCTION LAMP ID

No.
1 Ignition 10V-16V input
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Park brake Low side switch input LP3
5 Alternator Alternator D input LP4
6 Not used
7 Crab steering Low side swtich input LP6
8 Neutral High side switch input
9 Seal switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving beams High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
 Copyright ©

20 SECTION 55 - ELECTRICAL SYSTEM

20 Fuel sender Variable resistance input LP27

21 Transmission temperature sender Variable resistance input
22 Water temperature sender Variable resistance input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Trans oil pressure Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Buzzer Open collector output
36 Ground Ground

Instrument calibrations
GAGE TYPE INPUT READING POINTER INPUT CALIBRATION
TOLERANCE TOLERANCE DIRECTION
0 Hz 0 rpm ± 3% N/A Descending
Tach 307 Hz 1000 rpm N/A ± 60 rpm Ascending
736 Hz 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty • 0/-6% 230-240 OHMS Descending
(Ref)
Level fuel
102 OHMS 1/2 tank ± 3% (Ref) 98-108 OHMS Descending
33 OHMS Full • 4/-2% 33-42 OHMS Ascending
900 OHMS Point B ± 5% N/A Descending
Transmission
temperature 114 OHMS 105.5 °C ± 3% 111-117 OHMS Ascending
(Red/green line) (Ref)
700 OHMS Point A ± 5% N/A Descending
Coolant
temperature 95 OHMS 110 °C ± 3% 93-97 OHMS (Ref) Ascending
(Red/green line)
11 V Left red/green line ± 3% 10.7-11.3 V (Ref) Descending
Volt
15.9 V Right red/green line ± 5% 15.0-15.6 V (Ref) Ascending
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 21

Other calibrations

INDICATOR READING RESISTANCE Ω

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Brake temperature 150 °C 30-45
Coolant temperature (buzzer) 112 °C 70-83
 Copyright ©

22 SECTION 55 - ELECTRICAL SYSTEM

AIR CONDITIONER SCHEMATIC

1
3

87a
30

86
87
85
M
- +
10 11
9

Off

Off

Off
4
L M H

4
I H ML C

A S
12
5

X111 X110 S45

2 1 10 11

X111 X110 S45 X1

pos 8

+15 +30 +15

F27181

S Evaporator box S45 11 way connector

1 3RD speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Ventilated electrical motor 11 Thermostat
4 1 and 2 speed resistor 12 12 V light
5 Electrical cock A Waterproof 2 way connection
X111 9 way connector B Waterproof 5 way connection
X110 2 way power connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 23

PILOT SCHEMATIC

TO SOLENOID
VALVES LINE
SAFETY
SWITCH
LVC RIGHT
JOYSTICK
LEFT
JOYSTICK
1 A B
X72 X23 X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 1 2
X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X14 X14 X14 X14 X14 X14 X4 X4

N1
M-N1
G-R1

G-N1

M-B1
G-V1

B-G1

C-N1
A-R1
A-N1

B-R1
L-G1

V-N1
L-R1

Z-B1

V-B1
H1.5

N1.5

L-B1
H-G1.5

A1
L1
H-N1.5

K1 86 87a 87

85 30
N1

H-N1
H-R1.5

1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 1 2 1 2 A B A B 1 2
X13 X13 X13 X13 X13 X17 X17 YP4 YP4 YP3 YP3 YP6 YP6 YP5 YP5 YP7 YP7 YP8 YP8 XL XL XL XR XR XR X11 X11 X12 X12 X1 X1 X2 X2 X27 X27

CONNECTION
PRESS. SW
PRESS. SW
RETRACT
EXTEND
RH DOWN

JOYSTICK

PATTERN
JOYSTICK

PATTERN
LH DOWN

HORN JUMPER
RH STAB.

RH STAB.
LH STAB.

LH STAB.

VALVE 1

VALVE 2
PLUG 4

PLUG 3

PLUG 6

PLUG 5

PLUG 7

PLUG 8
MAINFOLD

RH UP
LH UP
POWER

P4

P3

P6

P5

P7

P8

R
L

2
B-R1
B-R1
H1.5

H-G1.5
H-N1.5

H-R1.5

N1

N1

N1
N1

1 2 3 4 5 6 1 2 1 2
X24 X24 X24 X24 X24 X24 YP9 YP9 YP10 YP10
AUX FORWARD
P10 PLUG 10
AUX REVERSE

LEFT
PLUG 9
N1

JOYSTICK
P9

2 5 3 6 7 8 2 3 7
S1 S1 S1 S1 S1 S1 S2 S2 S2

PILOT ON/OFF PATTERN

SWITCH SWITCH

31 31

F27182
 Copyright ©

24 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 25

2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB

FUSES AND RELAIS DESCRIPTION

NAME DESCRIPTION
Rear windshield wiper, rear windshield wiper switch and K12
F1A

C1
rear windshield washer (15 A)
K10 K11
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A)

11
6

4
F1C Stop lights switch (10 A)

7
BZ1

XC2
XC1
Instruments power supply, switches lamps, brake oil
F2A

D1

D5
D3
1
level sensor, seat, buzzer (15 A)

5
K2
F1/C F2/C

7
F2B Conditioner (15 A)
D6
D4

F2C Pilot control (15 A)

21
11
F1/B F2/B

1
8
Rear right/front left side lights, instruments illumination,

XC6
D2
F3A F1/A F2/A
conditioner switch illumination (3 A)

XC3
F3B Rear left/front right side lights, number plate light (3 A) F3/C F4/C

13

7
Front work light, tools rapid connection, Glide Ride
F3C F3/B F4/B K3
control, double delivery, cold start switches (10 A)

12
1
EGS power supply, clutch shut off button, differential F3/A F4/A
F4A K4
lock switch, 4WD switch (7.5 A)

21
11
F4B Rear hammer button, grab level valve and sensor (10 A)

17
9
Rear excavator lock, rear translation lock, rear work F5/C K5

XC4
F4C
light (10 A)

XC5
F5A Front inner work lights (15 A) F5/B
K6
F5B Traffic lights (10 A) F5/A
12
1

10
1

F5C Main beam (15 A) K7

F6/C F7/C F8/C
F6A Beacon lamp (7.5 A)
K8
F6B (+ 15) Warning (7.5 A) F6/B F7/B F8/B
F6C Hand hammer (7.5 A) F6/A F7/A F8/A K9
F7A (+30) Warning, (+30) antitheft, horn (10 A) GND
1B020309
+15V

+30V

F7B Current intake, radio, roof lamp (10 A)

J1

J3
J2

F7C Front windshield wiper (6 A)

F27183
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
 Copyright ©

26 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K2 Speed alarm, hand brake relay
K12

C1
K3 Starting relay
K10 K11
K4 Grab level solenoid valve relay

11
6

7
K5 Traffic and main beam lights relay BZ1

XC2
XC1
K6 Inner front work lights relay

D1

D5
D3
1

5
K2
K7 Inner rear work lights relay
F1/C F2/C

7
D6
D4
K8 Outer front work lights relay

21
11
F1/B F2/B

1
8
K9 Outer rear work lights relay

XC6
D2
K10 Optional relay F1/A F2/A

XC3
K11 Not connected relay
F3/C F4/C

13
K12 Flasher

7
F3/B F4/B K3

12
1
v F3/A F4/A
K4

21
11

17
9
F5/C K5

XC4

XC5
F5/B
K6
12 F5/A
1

10
1 K7
F6/C F7/C F8/C
K8
F6/B F7/B F8/B

F6/A F7/A F8/A K9

GND
1B020309
+15V

+30V
J1

J3
J2

F27183
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 27

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION

BS1 Right speaker (optional) M7 Front windshield washer
BS2 Left speaker (optional) M8 Blower motor
BZ1 Alarm buzzer M9 Optional blower motor
EV0 Fuel shut off solenoid valve M10 A/C compressor
EV1 Double delivery solenoid valve (optional) R2 Engine water temperature sender
EV2 Hand hammer solenoid valve (optional) R3 Fuel level sender
EV3 Rear hammer solenoid valve (optional) R4 Transmission oil high temperature sender
EV4 Rear translation solenoid valve S2 4WD switch
EV5 Excavator rear lock solenoid valve (optional) S3 Hand hammer switch (optional)
EV6 Grab level solenoid valve S4 Double delivery switch (optional)
EV8 Differential lock solenoid valve S5 Ride control switch (optional)
EV11 Ride control solenoid valve (optional) S6 Tools switch (optional)
EV12 Tools solenoid valve (optional) S7 Rear translation lock switch
EV24 Lifting solenoid valve (optional) S8 Excavator rear lock switch (optional)
EV25 Lifting solenoid valve (optional) S9 Lights switch
FG1 General fuse 80 A S11 Front work light switch
FG2 A/C fuse 10 A S12 Rear work light switch
G1 Battery S15 Beacon lamp switch
G2 Generator S17 Starting switch
H1 Excavator rear lock warning light S18 Handbrake switch
H2 Front left light S20 Engine oil low pressure switch
H3 Front right light S21 Air filter blocked switch
H4 Rear left light S24 Transmission oil pressure switch
H5 Number plate lamp S26 Clutch shut off button
H6 Rear right light S28 Grab sender
H11 Outer front left work light S29 Front horn button
H12 Outer front right work light S30 Rear hammer pedal button (optional)
H13 Outer rear left work light S31 Brake oil level sender
H14 Outer rear right work light S32 Stop light switch
H15 Beacon lamp S33 Stop light switch
H16 Beacon lamp S34 Roof lamp left switch
H17 Current intake illumination S35 Roof lamp right switch
H18 Cab lamp S36 A/C pressure switch
H19 Inner front left work light (optional) S41 Windshield wiper - Lights switch
H20 Inner front right work light (optional) S43 Radio (optional)
H21 Inner rear left work light (optional) S44 Seat (optional)
H22 Inner rear right work light (optional) S45 Conditioner and blower motor switch
HA1 Reverse speed buzzer S46 Current intake
HA2 Horn S47 Differential lock switch
HA3 Buzzer optional S48 EGS manual - auto switch
K01 Starter relay S49 Main switch
K02 A/C relay S50 EGS switch
K13 Antitheft unit S52 Solenoid valves lock switch (optional)
K14 Transmission detachment relay S53 Rear windshield washer-wiper switch
KC Fuses-relays board S54 Rear horn button (optional)
M4 Rear windshield wiper motor S68 Cold start temperature switch
M5 Front windshield wiper motor ST2 Front panel
M6 Rear windshield washer
 Copyright ©

28 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION

General cable - engine cable 18 way Front right work light (optional) 4 way
X1 X45
connector connector
X2 Horn/left light 7 way connector X46 Rear left work light (optional) 4 way connector
X3 Fuel shut off 3 way connector X47 Rear left work light 4 way connector
X4 Air filter 2 way connector Rear left light predisposition for version 4 way
X48
X7 Reverse buzzer 2 way connector connector
General cable-front dashboard 9 way X49 Front windshield wiper 6 way connector
X9
connector X50 Front left work light (optional) 4 way connector
Solenoid valves cable-general cable 24 way X51 Front left work light 4 way connector
X10
connector Front left indicator predisposition for version 4
X52
X12 General cable-cab cable 5 way connector way connector
General cable-front dashboard 17 way X53 Radio (brown colour) 8 way connector
X13
connector X54 Radio (black colour) 8 way connector
X14 Antitheft 11 way connector X55 Current intake 2 way connector
X15 Start switch 10 way connector X56 Front windshield washer 2 way connector
X16 Optional 1 way connector X57 Rear windshield washer 2 way connector
X17 Antitheft 11 way connector X61 Wiper and lights switch 12 way connector
X21 Cold start 6 way connector X63 Number plate light 12 way connector
X22 Right light 5 way connector X64 Optional conditioner 1 way connector
X23 EGS 9 way connector X67 Generator 3 way connector
Rear translation lock solenoid valve 2 way X70 Front panel 12 way connector
X24
connector X71 Starting switch 10 way connector
Excavator rear lock solenoid valve 2 way X72 Pilot control cable 1 way connector
X25
connector
X73 Engine oil pressure switch 1 way connector
X26 Grab sender 3 way connector
X80 Beacon lamp 2 way connector
X27 Pilot control horn button 2 way connector
X81 Beacon lamp 2 way connector
Clutch shut off button and differential lock
X28 X82 EGS system 9 way connector
switch 4 way connector
X83 EGS switch 19 way connector
X29 Grab level 2 way connector
X84 Transmission extension 13 way connector
Double delivery solenoid valve 2 way
X30 X85 Transmission 12 way connector
connector
Tools rapid connection solenoid valve 2 way General cable - right dashboard 13 way
X31 X87
connector connector
X32 Rear hammer solenoid valve 2 way connector General cable - left dashboard 9 way
X88
connector
Differential lock solenoid valve 2 way
X33 X89 Front left lights 6 way connector
connector
X34a Ride control solenoid valve 2 way connector X102 Rear axle sensor 3 way connector
X35 Hand hammer solenoid valve 2 way connector X103 Relay 2 way connector
X36 Rear hammer button 2 way connector Solenoid valve lock switch kit supply 1 way
X104
connector
Rear right light predisposition for version 4
X37 X110 Conditioner 2 way connector
way connector
X38 Rear right work light 4 way connector X111 Conditioner 9 way connector
X39 Rear windshield wiper 4 way connector X124 Lifting solenoid valve 2 way connector
Rear right work light (optional) 4 way X125 Lifting solenoid valve 2 way connector
X40 XA Horn cable 2 way connector
connector
X41 Optional blower motor 2 way connector XC1 On board 11 way connector
Front right indicator predisposition for version XC2 On board 7 way connector
X42
4 way connector XC3 On board 21 way connector
X43 Beacon lamp 4 way connector XC4 On board 21 way connector
X44 Front right work light 4 way connector XC5 On board 17 way connector
XC6 On board 13 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 29

NAME DESCRIPTION
XD Fuel shut off diode 2 way connector
XD1 Parking brake diode 2 way connector
XST2 Front panel 36 way connector
 Copyright ©

30 SECTION 55 - ELECTRICAL SYSTEM

ENGINE LINE

ST2
58 15/54 50 15.5
25 18.6
30

P0 12
12.4
20 21.7 MPH
35 km/h

9.3
15
1 2

S17
n/min
30 RED
6.2
10 0.344
TYP.-4
4

18.4-26

x1 000
0 3

.220

1 2 3 4 5 7 10 12 15 17 19 20 21 22 24 25 31 33 34 35 36
5 6 2 8 XST2

M1
G1
X15 X15 X15 X15

B1

S1

V1

G-R1

R-G1
Z1
R-N1

B-G1

G-V1

G/N1

C-N1
S-N1
B-V1

V-N1

Z-B1
C-N1 7.4

1 2
XD1 XD1

R-N1 8.1
G/N1 8.2

G/R1
G/R1
S18 16 14
X13
7
X13
X13

A2.5 5 2
XC6 XC6
G-R1
A2.5 4.1
A2.5 B-V1 4.2
+15
A2.5 V1
3 4.4
R6 2.3

+30

1 2.3

K3 86 87a 87
2 4.3
L-N1

B-N1.5
B-N1.5

L-N1.5

85 30

+15

1 2 3 4 5 6 7 8 9 10 11 F1B F2C
7.5A 15A
X14
N1.5

N1.5

K13
L-N1 2.3
H/R1 KC
4.3
6 13 3 9 10 7
XC6 XC6 XC6 XC6 XC6 XC6
H2.5

G-V1.5 8.4
R10

B1
G-V1
B/N1

L1.5

1 11 8 13 12 9 16 7 GRID HEATER 1 10 15 2 14 5 3
X1 X1 X1 X1 X1 X1 X1 X1 X10 X1 X1 X1 X1 X1 X1
TO COLD
START KIT
M1
R10

L-N1.5

B1

G-R1
Z1
B-G1
B-N1

V/N1

Z-B1
H2.5

B-N1
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
K01 K02
86 87 86 87
1
X72
85 30 85 30

TO PILOT
R2.5
V2.5
G-V1.5
R4

CONTROL LINE
R2.5

l
XD

FG1 FG2
80A 10A
S1
S-N1

-
R16 XD
V-B1
L-N1
R25

R70 2 1 3
V-N1

X67 X67 X67

G1 A
B4

1 X68
M10 X64 1 1 A
12Vcc M1 2 X3 X73 X4
X69 G2 R2 R3 R4
30
M
50
S36 M
D+ EV0 S68 S20 S21 S24
30 G W
p 3 t p p p
N70

U
t t
1
S49 X69
31
B
C X4
N2.5

X68
N1

N1

N1

N1

N1

N1

N1
N70

31 2.1

F27488
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 31

SOLENOID VALVES LINE

R-N1 5.1
N1 4.1
C1 4.4

B-R1
Z/N1
1 3 4 2 4 5
CB A A B A B 3 1 6 4
A B

S50
EGS
S2 2
S3 3
S29 6
N1
S48 2 5

A B C D E F G H J K L M N P R S T U V
X83

M0.5

G0.5
R0.5

N0.5
H0.5
S0.5

V0.5

B0.5
B-M0.5
Z0.5
B-G0.5
L0.5

H-B0.5
B-V0.5

B-S0.5
L-B0.5
B-R1

H-L1

K14
85 87a 87

1 2 3 4 5 6 7 8
10 20 18 17
86 30
19 X23
X13 X13 X13 X13 X13

M-N1
M-V1
B-R1

B-R1

A-R1

A-B1

Z/N1
G/R1 7.1 5
X13
B-R1
C-L1
M/B1

H-N1

M-B1
A-B1

C1
4.1
7 2 6 11 6 11 5 1 9 3
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1 XC1 XC1

F6C 70
7,5A 5.2
+15 +15 1.4
1

+15
F4A F4B
7.5A 10A
1.4
3

K10 K4 K2
86 87a 87 86 87a 87 86 87a 87

85 30 85 30 85 30

KC
1 6 9 19 16 5 8 11 8 1
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6

L-N1 C1
1.1 7.1
1 2 3 4 5 6 7 8 9 10 11 12 13
R-V1

M-N1
M-V1

M-B1

X84
C1
H-N1

A-G1

H-R1
R-V1
H-L1

18 10 12 7 28 21 26 29 11 8 6 20 4 17
X1 X10 X10 X10 X10 X10 X10 X10 X10 X10 X1 X10 X1 X1
H-R1

M0.5

G0.5
H0.5

R0.5
N0.5
V0.5

B0.5

S0.5

M-B0.5
Z0.5
L0.5

B-V0.5
R-V1

2
H-N1
C-L1

X36

S30

M L K J H G F E D C B A
1 X85
X36
C1
A-G1

H-R1
B-R1

A-R1

R-V1
R-V1

1 2 1 2 1 2 C A B 1 2 2 1 1
X32 X32 X33 X33 X35 X35 D C A X26 X26 X26 X29 X29 X27 X27 X7
EV3 EV8 EV2 X28 X28 X28
S28 EV6 TO PILOT HA1
1

N1

CONTROL HORN
S26 S47
2

2
X7
N2.5
N2.5
N1

N1

N1
N1

1.5
31 31 3.1

F27489
 Copyright ©

32 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVES LINE

C/N1 C/N1 C/N1 7.5

C/B1 C/B1 6.2

A B
2 4
A B
2 4
A B
2 4
A B
2 4
B A
1 3
H1 A B
3 1 6 4

S4 3
S5 3
S6 3
S7 3
S8 2 4
S52 2 5

C/N1
A-N1

B-N1
L-G1

V/B1
N1

N1 6.1

L/G1
C-B1
6 3 2 7 10 9 9 1
X13 X13 X13 X88 X87 X88 X87 X104
A-N1

B-N1

C-B1
L-G1

V-B1

L/G1
C/B1 6.1

23 14 27 18 24
X10 X10 X10 X10 X10
V1
A-N1

B-N1

C-B1
L-G1

M1

M1

1 2 1 2 2 1 1 2 1 2 1 2 1 2
X30 X30 X34a X34a X31 X31 X24 X24 X25 X25 X124 X124 X125 X125
EV5
EV1 EV11 EV12 EV4 EV24 EV25
1
2

N1
N1

2.5
31 31 4.1

F27490
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 33

LIGHTS LINE

R/N1

15/1 30/3 R/7 4 6 1 3

0 1 C BA

S42 49/4 30b/2 49a/5 L/6

S9 5 2

R1.5
R2.5

G1.5
H-N1.5
4 5 6 3
X87 X87 X87 X87
2.5
N1

S31
L-N1 7.1
V-N1.5 7.1

1.5
G-R1

B/R1 5.1
12 13 4 11 8
X13 X13 X13 X13 X13
B-V1 H/R1

H-N1.5
V-N1.5
G-N1

1.5
H-R1

R/N1

H/R1
G1.5

H-L1

L-N1

R1.5
R2.5
1.1

8 2 3 18 6 21 10 10 9 3 8 16 20 5 2 4 4 13 2
XC1 XC1 XC2 XC4 XC4 XC4 XC1 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC1 XC4 XC5

+30 +15 +15 L1 7.1

F1C F6B F5B F5C F2A F7A
10A 11 5.1 7,5A 10A 15A 15A 10A L1 5.1
10 5.1
A1 5.1
+15 +15 +30 A1 7.1

F3B F3A K12 + K5 86 87a 87

3A 3A L C
51 8.3
85 30
-

BZ1

KC 2 50
1.4 7.5
10
XC3 1.5
V1
A-B1

A-B1
2.3
2.5
C1
G1
C1

H/R1

6 7 1 4 5 2 3 1 4 5 2 3
X21 X21 X21 X21 X21 X22 X22 X22 X22 X22
G1
C1

N1
H1

H1
V1

V1
A1
L1
H/R1

1 2
XA XA
C1

H-R1

1 2 3 5 4 1 2 3 5 4
X89 X89 X89 X89 X89 X101 X101 X101 X101 X101

H2 H3
HA2
R
L
56b

56a

58

56b

56a

58
31

31

3.5
31 31 5.1

F27491
 Copyright ©

34 SECTION 55 - ELECTRICAL SYSTEM

REAR LIGHTS LINE

2.5
R-N1

4.2
B/R1

B/R1
S32 S33

4.5
L1

4.5
A1
R1
A1

R-N1
L1

19 17 7 8 9 6 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC5

2.2
70
71 7.5
4.2
11

NOT CONNECTED RELAY

K11

4.2
10 52 8.3

KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1

R-N1
L1

G1 8.3
G1

G1
A1
G-N1

G-N1

G-N1
R-N1

R-N1

R-N1
L1

5 2 6 4 3 9 8 10 7 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X8 X52 X48 X42 X37
G1
N1

N1

N1
A1
G-N1

G-N1
R-N1

R-N1
L1

N1
G-N1

2 1
X63 X63
H4 H6
H5
59c

59c
R
L

58

58
31

31

4.5
31 31 6.1

F27492
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 35

WORK LIGHTS LINE

C/N1 C/N1 7.1

3.5
C/B1

2 4 2 4
A B A B

S11 3
S12 3

N1
3.5
N1 N1 N1 7.1
S-G1

Z-N1

C/B1
12
1 11 7 X87
X87 X87 X87
S-G1

Z-N1

C/B1

N1
C/B1

3 14 4 12 14 13 15 11 18
XC3 XC5 XC3 XC5 XC3 XC5 XC3 XC5 XC3

F4C
10A
+30 +30 +30 +30 H1
V1

H-N1

V-N1
+15
F5A F8B F8C F8A
15A 15A 15A 15A

K6 86 87a 87
K8 86 87a 87
K7 86 87a 87
K9 86 87a 87

85 30 85 30 85 30 85 30

KC

3.5
C/B1
N1

H1

N1

H1

N1

N1
V1

H-N1

H-N1

V-N1
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X51 X50 X44 X45 X47 X46 X38 X40

H11 H19 H12 H20 H13 H21 H14 H22

N1

5.5
31 31 7.1

F27493
 Copyright ©

36 SECTION 55 - ELECTRICAL SYSTEM

WINDSHIELD WIPER WASHER LINE

R-N1 8.1
6.5
C/N1

3.5
C/N1

5 S53 57/58 56b 56a 54S 54D 53 31b 49

H15 H16
A B 0 12 R
3 1 6 4 9 0 2 4
2 1 0 A B M M
L
S54 6
S41 56 30 L 15 31
2 5 7
S15 3

A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X80 X80 X81 X81

R-N1
X61

V-N1.5

A1
G/R1

L1
A/N1
A/R1
A/B1

L-N1
N1

M1
6.5

L1
A1

C/N1
4.5
L-N1 HA3
4.5 1 2 3 4
L1

A-G1.5
4.5 X43
2.1
G/R1
4.5
V-N1.5
A/N1

A/R1

A/B1

L-B1
L/B1

1.5
C-N1 21 1 2
6 5 1 2 4 3 9 X13 X13 X87
X88 X88 X88 X88 X88 X88 X13

2.3
C1

A-G1.5

A-G1.5
A-V1.5

Z1
Z1
R/N1

C/N1
A/B1
4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3

F7C
6A A.R. F6A F3C
7,5A 10A

+15 +15 +15

5.3
71

+15

F1A
15A

4.4
50
KC
17
XC3

5 6 5 4 1 2 3
X10 X10 X12 X12 X12 X12 X12
R/N1
A/N1

A/N1

A/B1

- l 4 1 2 3 - l - l 6 3 4 1
X41 X41 X39 X57 X57 X56 X56 X49
M4 M6 M7 M5
M9 53a 53a
53 M 53b M M 53 M53b
31b 31b

31 31
N1.5
N1.5
N1.5

N1
N1

N1

N1

N1
N1

6.5
31 31 8.1

F27494
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 37

HEATER LINE

5.5
G1
BS2 OFF
0

G1
S43 ON
S46 H17 1 2 3 4 5 6 7 8 9 10 11
S45
H18
BS1

H1
B1
V1
S1
A1
G1.5
R1.5
C1.5
Z2.5

G-V1.5
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
X53 X54 l -
X55 X55

R-N1

N0.5
R0.5
N0.5
R0.5

N1

M-N1
B/R1
R-N1

N1
G-V1.5
1.1

R-N1

N1
1.5
R-N1
R-N1

7.5

N4
X14

G/N1 S34 S35

1.5
4
R-N1.5

X14

G/N1

R-N1.5

Z2.5

R4
1 2 1 2 3 4 5 6 7 8 9
11 12 10 4 X110 X111
XC6 XC6 XC5 XC6
R-N1
N1

1 2 3 4
X17

S44 F7B F2B

10A 15A

+30 +15

4.4
51

5.2
52
+30

KC
N1.5

7.5
31

F27486
 Copyright ©

38 SECTION 55 - ELECTRICAL SYSTEM

COLD START KIT

CONTROLLER

1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82

G1
R1

N1

M1

N1
S1
B-N1

V-B1
L-N1

1 2
X83 X83

1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER

RELAY
TO ENGINE LINE

F27176
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 39

SIDE INSTRUMENT

Functional description

PIN NAME FUNCTION LAMP ID

No.
1 Ignition 10V-16V input
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Park brake Low side switch input LP3
5 Alternator Alternator D input LP4
6 Not used
7 Crab steering Low side swtich input LP6
8 Neutral High side switch input
9 Seal switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving beams High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
 Copyright ©

40 SECTION 55 - ELECTRICAL SYSTEM

20 Fuel sender Variable resistance input LP27

21 Transmission temperature sender Variable resistance input
22 Water temperature sender Variable resistance input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Trans oil pressure Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Buzzer Open collector output
36 Ground Ground

Instrument calibrations
GAGE TYPE INPUT READING POINTER INPUT CALIBRATION
TOLERANCE TOLERANCE DIRECTION
0 Hz 0 rpm ± 3% N/A Descending
Tach 307 Hz 1000 rpm N/A ± 60 rpm Ascending
736 Hz 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty • 0/-6% 230-240 OHMS Descending
(Ref)
Level fuel
102 OHMS 1/2 tank ± 3% (Ref) 98-108 OHMS Descending
33 OHMS Full • 4/-2% 33-42 OHMS Ascending
900 OHMS Point B ± 5% N/A Descending
Transmission
temperature 114 OHMS 105.5 °C ± 3% 111-117 OHMS Ascending
(Red/green line) (Ref)
700 OHMS Point A ± 5% N/A Descending
Coolant
temperature 95 OHMS 110 °C ± 3% 93-97 OHMS (Ref) Ascending
(Red/green line)
11 V Left red/green line ± 3% 10.7-11.3 V (Ref) Descending
Volt
15.9 V Right red/green line ± 5% 15.0-15.6 V (Ref) Ascending
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 41

Other calibrations

INDICATOR READING RESISTANCE Ω

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Brake temperature 150 °C 30-45
Coolant temperature (buzzer) 112 °C 70-83
 Copyright ©

42 SECTION 55 - ELECTRICAL SYSTEM

AIR CONDITIONER KIT

1
3

87a
30

86
87
85
M
- +
10 11
9

Off

Off

Off
4
L M H

4
I H ML C

A S
12
5

X111 X110 S45

2 1 10 11

X111 X110 S45 X1

pos 8

+15 +30 +15

F27181

S Evaporator box S45 11 way connector

1 3RD speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Ventilated electrical motor 11 Thermostat
4 1 and 2 speed resistor 12 12 V light
5 Electrical cock A Waterproof 2 way connection
X111 9 way connector B Waterproof 5 way connection
X110 2 way power connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 43

PILOT LINE

TO SOLENOID
VALVES LINE
SAFETY
SWITCH
LVC RIGHT
JOYSTICK
LEFT
JOYSTICK
1 A B
X72 X23 X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 1 2
X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X14 X14 X14 X14 X14 X14 X4 X4

N1
M-N1
G-R1

G-N1

M-B1
G-V1

B-G1

C-N1
A-R1
A-N1

B-R1
L-G1

V-N1
L-R1

Z-B1

V-B1
H1.5

N1.5

L-B1
H-G1.5

A1
L1
H-N1.5

K1 86 87a 87

85 30
N1

H-N1
H-R1.5

1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 1 2 1 2 A B A B 1 2
X13 X13 X13 X13 X13 X17 X17 YP4 YP4 YP3 YP3 YP6 YP6 YP5 YP5 YP7 YP7 YP8 YP8 XL XL XL XR XR XR X11 X11 X12 X12 X1 X1 X2 X2 X27 X27

CONNECTION
PRESS. SW
PRESS. SW
RETRACT
EXTEND
RH DOWN

JOYSTICK

PATTERN
JOYSTICK

PATTERN
LH DOWN

HORN JUMPER
RH STAB.

RH STAB.
LH STAB.

LH STAB.

VALVE 1

VALVE 2
PLUG 4

PLUG 3

PLUG 6

PLUG 5

PLUG 7

PLUG 8
MAINFOLD

RH UP
LH UP
POWER

P4

P3

P6

P5

P7

P8

R
L

2
B-R1
B-R1
H1.5

H-G1.5
H-N1.5

H-R1.5

N1

N1

N1
N1

1 2 3 4 5 6 1 2 1 2
X24 X24 X24 X24 X24 X24 YP9 YP9 YP10 YP10
AUX FORWARD
P10 PLUG 10
AUX REVERSE

LEFT
PLUG 9
N1

JOYSTICK
P9

2 5 3 6 7 8 2 3 7
S1 S1 S1 S1 S1 S1 S2 S2 S2

PILOT ON/OFF PATTERN

SWITCH SWITCH

31 31

F27182
 Copyright ©

44 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 45

2.3 ELECTRICAL DIAGRAMS - 4WS

FUSES AND RELAIS DESCRIPTION

NAME DESCRIPTION
Rear windshield wiper, rear windshield wiper switch and
F1A K12
rear windshield washer (15 A)

C1
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A) K10 K11

F1C Stop light switch (10 A)

11
6

7
BZ1

XC2
XC1
Instruments power supply, switches lamps, brake oil
F2A

D1

D5
D3
level sensor, seat, buzzer (15 A)

5
K2
F2B Conditioner (15 A) F1/C F2/C

7
D6
D4

F2C Pilot control (15 A)

21
11
F1/B F2/B

1
8
Rear right/front left side lights, instruments illumination,
F3A

XC6
D2
conditioner switch illumination (3 A) F1/A F2/A

XC3
F3B Rear left/front right side lights, number plate light (3 A)
F3/C F4/C

13
Front work light, tools rapid connection, Glide Ride

7
F3C
control, cold start switches (10 A) F3/B F4/B K3
EGS power supply, clutch shut off button, 4WD switch

12
1
F4A F3/A F4/A
(7.5 A) K4

21
11
F4B Rear hammer button, grab level valve and sensor (10 A)

17
9
Power supply 4WS unit, 4WS switch, rear excavator
F4C F5/C K5
XC4
lock, rear translation lock, rear work light (10 A)

XC5
F5A Front inner work lights (15 A) F5/B
K6
F5B Traffic lights (10 A)
F5/A
12
1

10
1

F5C Main beam (15 A) K7

F6A Beacon lamp (7.5 A) F6/C F7/C F8/C

F6B (+15) Warning (7.5 A) K8

F6/B F7/B F8/B
F6C Hand hammer (7.5 A)
F6/A F7/A F8/A K9
F7A (+30) Warning, (+30) antitheft, horn (10 A)
GND
1B020309
+15V

F7B Current intake, radio, roo65f lamp (10 A)

+30V
J1

J3

F7C Front windshield wiper (6 A)

J2

F27183
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
 Copyright ©

46 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K2 Speed alarm, hand brake relay K12

C1
K3 Starting relay K10 K11
K4 Grab level solenoid valve relay

11
6

7
BZ1

XC2
K5 Traffic and main beam lights relay

XC1
K6 Inner front work lights relay

D1

D5
D3
1

5
K2
K7 Inner rear work lights relay F1/C F2/C

7
D6
D4

K8 Outer front work lights relay

21
11
F1/B F2/B

1
8
K9 Outer rear work lights relay

XC6
D2
K10 Optional relay F1/A F2/A

XC3
K11 Not connected relay F3/C F4/C

13

7
K12 Flasher
F3/B F4/B K3

12
1
F3/A F4/A
K4

21
11

17
9
F5/C K5

XC4

XC5
F5/B
K6

12
F5/A
1

10
1
K7
F6/C F7/C F8/C
K8
F6/B F7/B F8/B

F6/A F7/A F8/A K9

GND
1B020309
+15V

+30V
J1

J3
J2

F27183
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 47

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION

BS1 Right speaker (optional) KC Fuses-relays board
BS2 Left speaker (optional) KS Steering unit
BZ1 Alarm buzzer M1 Starter motor
EV0 Fuel shut off solenoid valve M2 Fuel pump
EV1 Double delivery solenoid valve (optional) M4 Rear windshield wiper motor
EV2 Hand hammer solenoid valve (optional) M5 Front windshield wiper motor
EV3 Rear hammer solenoid valve (optional) M6 Rear windshield washer
EV4 Rear translation solenoid valve M7 Front windshield washer
EV5 Excavator rear lock solenoid valve M9 Optional blower motor
EV6 Grab level solenoid valve M10 A/C compressor
EV11 Ride control solenoid valve (optional) R2 Engine water temperature sender
EV12 Tools solenoid valve (optional) R3 Fuel level sender
EV24 Lifting solenoid valve (optional) R4 Transmission oil high temperature sender
EV25 Lifting solenoid valve (optional) S2 4WD switch
EVA2 Crab steering solenoid valve S3 Hand hammer switch (optional)
EVA3 4 wheels steering enable solenoid valve S4 Double delivery switch (optional)
EVB2 4 wheels steering selection solenoid valve S5 Ride control switch (optional)
Normal steering (front wheels only) enable S6 Tools switch (optional)
EVB3
solenoid valve S7 Rear translation lock switch
FG1 General fuse 80 A S8 Excavator rear lock switch
FG2 A/C fuse 10 A S9 Lights switch
G1 Battery S11 Front work light switch
G2 Generator S12 Rear work light switch
H1 Excavator rear lock warning light S15 Beacon lamp switch
H2 Front left light S17 Starting switch
H3 Front right light S18 Handbrake switch
H4 Rear left light S20 Engine oil low pressure switch
H5 Number plate lamp S21 Air filter blocked switch
H6 Rear right light S24 Transmission oil pressure switch
H11 Outer front left work light S26 Clutch shut off button
H12 Outer front right work light S28 Grab sender
H13 Outer rear left work light S29 Front horn button
H14 Outer rear right work light S30 Rear hammer pedal button (optional)
H15 Beacon lamp S31 Brake oil level sender
H16 Beacon lamp S32 Stop light switch
H17 Current intake illumination S33 Stop light switch
H18 Cab lamp S34 Roof lamp left switch
H19 Inner front left work light (optional) S35 Roof lamp right switch
H20 Inner front right work light (optional) S36 A/C pressure switch
H21 Inner rear left work light (optional) S39 Rear axle sensor
H22 Inner rear right work light (optional) S40 Front axle sensor
HA1 Reverse speed buzzer S41 Windshield wiper - Indicators switch
HA2 Horn S42 Hazard
HA3 Buzzer optional S43 Radio (optional)
K01 Starter relay S44 Seat (optional)
K02 A/C relay S45 Conditioner and blower motor switch
K13 Antitheft unit S46 Current intake
K14 Transmission detachment relay S47 Steering switch
 Copyright ©

48 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION

S48 EGS manual-auto switch X39 Rear windshield wiper 4 way connector
S49 Main switch X40 Rear right work light (opt) 4 way connector
S50 EGS switch X41 Optional blower motor 2 way connector
S52 Solenoid valves lock switch (optional) Front right indicator predisposition for
X42
S53 Rear windshield washer-wiper switch version 4 way connector
S54 Rear horn button (optional) X43 Beacon lamp 4 way connector
S68 Cold start temperature switch X44 Front right work light 4 way connector
ST2 Front panel Front right work light (optional) 4 way
X45
General cable-Engine cable 18 way connector
X1 Rear left work light (optional) 4 way
connector X46
X2 Cold start cable 6 way connector connector
X3 Fuel shut off 3 way connector X47 Rear left work light 4 way connector
X4 Air filter 2 way connector Rear left light predisposition for version 4
X48
way connector
X7 Reverse buzzer 2 way connector
X49 Front windshield wiper 6 way connector
General cable-front dashboard 13 way
X9 Front left work light (optional) 4 way
connector X50
connector
Solenoid valves cable-General cable 29
X10 X51 Front left work light 4 way connector
way connector
X12 General cable-Cab cable 5 way connector Front left indicator predisposition for version
X52
4 way connector
General cable-Front dashboard 17 way
X13 X53 Radio (brown colour) 8 way connector
connector
X14 Antitheft 11 way connector X54 Radio (black colour) 8 way connector
X15 Start switch 10 way connector X55 Current intake 2 way connector
X16 Optional 1 way connector X56 Front windshield washer 2 way connector
X17 Antitheft 11 way connector X57 Rear windshield washer 2 way connector
X21 Horn/left 7 way connector X61 Wiper and lights switch 12 way connector
X22 Right light 5 way connector X63 Number plate light 2 way connector
X23 EGS 9 way connector X64 Optional conditioner 1 way connector
Rear translation lock solenoid valve 2 way X67 Generator 3 way connector
X24 X70 Front panel 12 way connector
connector
Excavator rear lock solenoid valve 2 way X71 Starting switch 10 way connector
X25
connector X72 Pilot control cable 1 way connector
X26 Grab sender 3 way connector X73 Engine oil pressure switch 1 way connector
X27 Pilot control horn button 2 way connector X80 Beacon lamp 2 way connector
Clutch shut off button and horn button 4 way X81 Beacon lamp 2 way connector
X28
connector X82 EGS system 9 way connector
X29 Grab level 2 way connector X83 EGS switch 19 way connector
Double delivery solenoid valve 2 way X84 Transmission extension 13 way connector
X30
connector X85 Transmission 12 way connector
Tools rapid connection solenoid valve 2 way General cable-right dashboard 13 way
X31 X87
connector connector
Rear hammer solenoid valve 2 way General cable-left dashboard 9 way
X32 X88
connector connector
X33 Bridge 2 way connector X89 Front left lights 6 way connector
X34a Ride control solenoid valve 2 way connector Circular steering solenoid valve 2 way
Hand hammer solenoid valve 2 way X91
X35 connector
connector X92 Crab steering solenoid valve 2 way connector
X36 Rear hammer button 2 way connector X93 4WS enable solenoid valve 2 way connector
Rear right light predisposition for version 4 X94 2WS enable solenoid valve 2 way connector
X37
way connector
X95 Steering unit 12 way connector
X38 Rear right work light 4 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 49

NAME DESCRIPTION
X96 Steering unit 8 way connector
X97 Front axle sensor 3 way connector
X98 Rear axle sensor 3 way connector
X102 Controller 10 way connector
X103 Relay 2 way connector
X104 Solenoid valve lock switch 1 way connector
X110 Conditioner 2 way connector
X111 Conditioner 9 way connector
X124 Lifting solenoid valve 2 way connector
X125 Lifting solenoid valve 2 way connector
XA Horn 2 way connector
XC1 On board 11 way connector
XC2 On board 7 way connector
XC3 On board 21 way connector
XC4 On board 21 way connector
XC5 On board 17 way connector
XC6 On board 13 way connector
XD Fuel shut off diode 2 way connector
XD1 Parking brake diode 2 way connector
XST2 Front panel 36 way connector
 Copyright ©

50 SECTION 55 - ELECTRICAL SYSTEM

ENGINE LINE

ST2
58 15/54 50 15.5
25 18.6
30

P0 12
12.4
20 21.7 MPH
35 km/h

9.3
15
1 2

S17
n/min
30 RED
6.2
10 0.344
TYP.-4
4

18.4-26

x1 000
0 3

.220

1 2 3 4 5 7 10 12 15 17 19 20 21 22 24 25 31 33 34 35 36
5 6 2 8 XST2

M1
G1
X15 X15 X15 X15

B1

S1

V1

G-R1

R-G1
Z1
R-N1

B-G1

G-V1

G/N1

C-N1
S-N1
B-V1

V-N1

Z-B1
C-N1 7.4

1 2
XD1 XD1

R-N1 8.1
G/N1 8.2

G/R1
G/R1
S18 16 14
X13
7
X13
X13

A2.5 5 2
XC6 XC6
G-R1
A2.5 4.1
A2.5 B-V1 4.2
+15
A2.5 V1
3 4.4
R6 2.3

+30

1 2.3

K3 86 87a 87
2 4.3
L-N1

B-N1.5
B-N1.5

L-N1.5

85 30

+15

1 2 3 4 5 6 7 8 9 10 11 F1B F2C
7.5A 15A
X14
N1.5

N1.5

K13
L-N1 2.3
H/R1 KC
4.3
6 13 3 9 10 7
XC6 XC6 XC6 XC6 XC6 XC6
H2.5

G-V1.5 8.4
R10

B1
G-V1
B/N1

L1.5

1 11 8 13 12 9 16 7 GRID HEATER 1 10 15 2 14 5 3
X1 X1 X1 X1 X1 X1 X1 X1 X10 X1 X1 X1 X1 X1 X1
TO COLD
START KIT
M1
R10

L-N1.5

B1

G-R1
Z1
B-G1
B-N1

V/N1

Z-B1
H2.5

B-N1
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
K01 K02
86 87 86 87
1
X72
85 30 85 30

TO PILOT
R2.5
V2.5
G-V1.5
R4

CONTROL LINE
R2.5

l
XD

FG1 FG2
80A 10A
S1
S-N1

-
R16 XD
V-B1
L-N1
R25

R70 2 1 3
V-N1

X67 X67 X67

G1 A
B4

1 X68
M10 X64 1 1 A
12Vcc M1 2 X3 X73 X4
X69 G2 R2 R3 R4
30
M
50
S36 M
D+ EV0 S68 S20 S21 S24
30 G W
p 3 t p p p
N70

U
t t
1
S49 X69
31
B
C X4
N2.5

X68
N1

N1

N1

N1

N1

N1

N1
N70

31 2.1

F27488
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 51

SOLENOID VALVES LINE

R-N1 5.1
N1 4.1
C1 4.4

B-R1
Z/N1
1 3 4 2 4 5
CB A A B A B 3 1 6 4
A B

S50
EGS
S2 2
S3 3
S29 6
S48 2 5

N1
A B C D E F G H J K L M N P R S T U V
X83

M0.5

G0.5
R0.5

N0.5
H0.5
S0.5

V0.5

B0.5
B-M0.5
Z0.5
B-G0.5
L0.5

H-B0.5
B-V0.5

B-S0.5
L-B0.5
M-V1
B-R1

K14
85 87a 87

1 2 3 4 5 6 7 8
10 20
86 30
19 X23
X13 X13 X13

M-N1
M-V1
B-R1

B-R1

A-R1

A-B1

Z/N1
G/R1 7.1 5
X13
B-R1
M/B1

H-N1

M-B1
A-B1

C1
4.1
7 2 6 11 6 11 5 1 9 3
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1 XC1 XC1

F6C 70
7,5A 5.2
+15 +15 1.4
1

+15
F4A F4B
7.5A 10A
1.4
3

K10 K4 K2
86 87a 87 86 87a 87 86 87a 87

85 30 85 30 85 30

KC
1 6 9 19 16 5 8 11 8 1
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6

L-N1 C1
1.1 7.1
1 2 3 4 5 6 7 8 9 10 11 12 13
R-V1

M-N1
M-V1

M-B1

X84
C1
H-N1

A-G1

H-R1
R-V1

18 10 7 6 12 24 29 11 8 9 4 17
X1 X10 X10 X1 X10 X10 X10 X10 X10 X10 X1 X1
M-B1
H-R1

M0.5

G0.5
H0.5

R0.5
N0.5
V0.5

B0.5

S0.5

M-B0.5
Z0.5
L0.5

B-V0.5
R-V1

2
H-N1

X36

S30

M L K J H G F E D C B A
1 X85
X36
C1
A-G1

H-R1
B-R1

A-R1

R-V1
R-V1

1 2 1 2 C A B 1 2 2 1 1
X32 X32 X35 X35 2 1 X26 X26 X26 X29 X29 X27 X27 X7
EV3 EV2 X28 X28
S26 S28 EV6 TO PILOT HA1
1

N1

CONTROL HORN
2

2
X7
N2.5
N2.5

N1

N1

N1

N1
N1

1.5
31 31 3.1

F27495
 Copyright ©

52 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVES LINE

C/N1 C/N1 C/N1 7.5

C/B1 C/B1 6.2

A B
2 4
A B
2 4
A B
2 4
A B
2 4
B A
1 3
H1 A B
3 1 6 4
1 0 2
B C F

S4 3
S5 3
S6 3
S7 3
S8 2 4
S52 2 5
S47 A E

C/N1
V1
A-N1

B-N1
L-G1

C/B1
N1

N1 6.1

V/N1
L-R1
L/G1
C-B1
6 3 2 8 9 10 9 1 3 2 1
X13 X13 X13 X87 X87 X87 X104 X50 X50 X50
X88
V1
A-N1

B-N1

C-B1
L-G1

L/G1
C/B1 4.1
C/B1 6.1

C/B1 6.1

L-R1 4.1
V/N1 4.1

L/R1 4.2
S/N1 4.2
H/N1 4.2
M/B1 4.3

M/B1
H/N1
S/N1
L/R1

23 13 27 18 21 25 17 15 22
X10 X10 X10 X10 X10 X10 X10 X10 X10
V1

M/B1
A-N1

B-N1

C-B1

H/N1
L-G1

S/N1
L/R1
M1

M1

1 2 1 2 2 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
X30 X30 X34a X34a X31 X31 X24 X24 X25 X25 X124 X124 X125 X125 X91 X91 X92 X92 X93 X93 X94 X94
EV5 EVA2 EVB2 EVA3 EVB3
EV1 EV11 EV12 EV4 EV24 EV25
1

1
2

N1
N1
N1

2.5
31 31 4.1

F27496
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 53

LIGHTS LINE

R/N1

15/1 30/3 R/7 4 6 1 3

0 1 C BA

S42 49/4 30b/2 49a/5 L/6

S9 5 2

R1.5
R2.5

G1.5
H-N1.5
4 5 6 3
X87 X87 X87 X87
2.5
N1

S31
L-N1 7.1
V-N1.5 7.1

1.5
G-R1

B/R1 5.1
12 13 4 11 8
X13 X13 X13 X13 X13
B-V1 H/R1

H-N1.5
1.1
V-N1.5
G-N1

1.5
H-R1

R/N1

H/R1
G1.5

H-L1

L-N1

R1.5
R2.5
8 2 3 18 6 21 10 10 9 3 8 16 20 5 2 4 4 13 2
XC1 XC1 XC2 XC4 XC4 XC4 XC1 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC1 XC4 XC5

+30 +15 +15 L1 7.1

F1C F6B F5B F5C F2A F7A
10A 11 5.1 7,5A 10A 15A 15A 10A L1 5.1
10 5.1
A1 5.1
+15 +15 +30 A1 7.1

F3B F3A K12 + K5 86 87a 87

3A 3A L C
51 8.3
85 30
-

BZ1

KC 2 50
1.4 7.5
10
XC3 1.5
V1
C1

Z/B1 M/B1
A-B1

1.5 3.5
2 1
A-B1 X33 X33
2.3 C1
H/N1 2.5
V-B1 3.5
1.4
3.5
S/N1
3.5
V/N1 3.5
L/R1
G1
C1

H/R1

6 7 1 4 5 2 3 1 4 5 2 3
X21 X21 X21 X21 X21 X22 X22 X22 X22 X22
G1
C1

N1
H1

H1
V1

V1
A1
L1
H/R1

1.5
V/B1

1.5
H1
26 16 14 19
X10 X10 X10 X10

3.5
L-R1

3.5
C/B1

1 2
R/N1
A/V1

H-L1

L/N1

XA XA
C1

N1

H1

M/B1
A-R1

H/N1

R/N1
V/N1

A-B1

S/N1
H-L1

V-B1

V/B1

L-N1
A/V1
Z/B1

L/R1
L/B1

C1

H-R1

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
X95 X96 1 2 3 5 4 1 2 3 5 4
X89 X89 X89 X89 X89 X101 X101 X101 X101 X101
C B A C B A
X97 X97 X97 X98 X98 X98 H2 H3
HA2
R
L
56b

56a

58

56b

56a

58

S40 S39
31

31
N1

KS

3.5
31 31 5.1

F27497
 Copyright ©

54 SECTION 55 - ELECTRICAL SYSTEM

REAR LIGHTS LINE

2.5
R-N1

4.2
B/R1

B/R1
S32 S33

4.5
L1

4.5
A1
R1
A1

R-N1
L1

19 17 7 8 9 6 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC5

2.2
70
71 7.5
4.2
11

NOT CONNECTED RELAY

K11

4.2
10 52 8.3

KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1

R-N1
L1

G1 8.3
G1

G1
A1
G-N1

G-N1

G-N1
R-N1

R-N1

R-N1
L1

5 2 6 4 3 9 8 10 7 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X8 X52 X48 X42 X37
G1
N1

N1

N1
A1
G-N1

G-N1
R-N1

R-N1
L1

N1
G-N1

2 1
X63 X63
H4 H6
H5
59c

59c
R
L

58

58
31

31

4.5
31 31 6.1

F27492
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 55

WORK LIGHTS LINE

C/N1 C/N1 7.1

3.5
C/B1

2 4 2 4
A B A B

S11 3
S12 3

N1
3.5
N1 N1 N1 7.1
S-G1

Z-N1

C/B1
12
1 11 7 X87
X87 X87 X87
S-G1

Z-N1

C/B1

N1
C/B1

3 14 4 12 14 13 15 11 18
XC3 XC5 XC3 XC5 XC3 XC5 XC3 XC5 XC3

F4C
10A
+30 +30 +30 +30
H1
V1

H-N1

V-N1
+15
F5A F8B F8C F8A
15A 15A 15A 15A

K6 86 87a 87
K8 86 87a 87
K7 86 87a 87
K9 86 87a 87

85 30 85 30 85 30 85 30

KC

3.5
C/B1
N1

H1

N1

H1

N1

N1
V1

H-N1

H-N1

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 V-N1
3 4
X51 X50 X44 X45 X47 X46 X38 X40

H11 H19 H12 H20 H13 H21 H14 H22

N1

5.5
31 31 7.1

F27493
 Copyright ©

56 SECTION 55 - ELECTRICAL SYSTEM

WINDSHIELD WIPER WASHER LINE

R-N1 8.1
6.5
C/N1

3.5
C/N1

5 S53 57/58 56b 56a 54S 54D 53 31b 49

H15 H16
A B 0 12 R
3 1 6 4 9 0 2 4
2 1 0 A B M M
L
S54 6
S41 56 30 L 15 31
2 5 7
S15 3

A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X80 X80 X81 X81

R-N1
X61

V-N1.5

A1
G/R1

L1
A/N1
A/R1
A/B1

L-N1
N1

M1
6.5

L1
A1

C/N1
4.5
L-N1 HA3
4.5 1 2 3 4
L1

A-G1.5
4.5 X43
2.1
G/R1
4.5
V-N1.5
A/N1

A/R1

A/B1

L-B1
L/B1

1.5
C-N1 21 1 2
6 5 1 2 4 3 9 X13 X13 X87
X88 X88 X88 X88 X88 X88 X13

2.3
C1

A-G1.5

A-G1.5
A-V1.5

Z1
Z1
R/N1

C/N1
A/B1
4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3

F7C
6A A.R. F6A F3C
7,5A 10A

+15 +15 +15

5.3
71

+15

F1A
15A

4.4
50
KC
17
XC3

5 6 5 4 1 2 3
X10 X10 X12 X12 X12 X12 X12
R/N1
A/N1

A/N1

A/B1

- l 4 1 2 3 - l - l 6 3 4 1
X41 X41 X39 X57 X57 X56 X56 X49
M4 M6 M7 M5
M9 53a 53a
53 M 53b M M 53 M 53b
31b 31b

31 31
N1.5
N1.5
N1.5

N1
N1

N1

N1

N1
N1

6.5
31 31 8.1

F27494
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 57

HEATER LINE

5.5
G1
BS2 OFF
0

G1
S43 ON
S46 H17 1 2 3 4 5 6 7 8 9 10 11
S45
H18
BS1

H1
B1
V1
S1
A1
G1.5
R1.5
C1.5
Z2.5

G-V1.5
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
X53 X54 l -
X55 X55

R-N1

N0.5
R0.5
N0.5
R0.5

N1

M-N1
B/R1
R-N1

N1
G-V1.5
1.1

R-N1

N1
1.5
R-N1
R-N1

7.5

N4
X14

G/N1 S34 S35

1.5
4
R-N1.5

X14

G/N1

R-N1.5

Z2.5

R4
1 2 1 2 3 4 5 6 7 8 9
11 12 10 4 X110 X111
XC6 XC6 XC5 XC6
R-N1
N1

1 2 3 4
X17

S44 F7B F2B

10A 15A

+30 +15

4.4
51

5.2
52
+30

KC
N1.5

7.5
31

F27486
 Copyright ©

58 SECTION 55 - ELECTRICAL SYSTEM

COLD START KIT

CONTROLLER

1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82

G1
R1

N1

M1

N1
S1
B-N1

V-B1
L-N1

1 2
X83 X83

1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER

RELAY
TO ENGINE LINE

F27176
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 59

SIDE INSTRUMENT

Functional description

PIN NAME FUNCTION LAMP ID

No.
1 Ignition 10V-16V input
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Park brake Low side switch input LP3
5 Alternator Alternator D input LP4
6 Not used
7 Crab steering Low side swtich input LP6
8 Neutral High side switch input
9 Seal switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving beams High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
 Copyright ©

60 SECTION 55 - ELECTRICAL SYSTEM

20 Fuel sender Variable resistance input LP27

21 Transmission temperature sender Variable resistance input
22 Water temperature sender Variable resistance input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Trans oil pressure Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Buzzer Open collector output
36 Ground Ground

Instrument calibrations
GAGE TYPE INPUT READING POINTER INPUT CALIBRATION
TOLERANCE TOLERANCE DIRECTION
0 Hz 0 rpm ± 3% N/A Descending
Tach 307 Hz 1000 rpm N/A ± 60 rpm Ascending
736 Hz 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty • 0/-6% 230-240 OHMS Descending
(Ref)
Level fuel
102 OHMS 1/2 tank ± 3% (Ref) 98-108 OHMS Descending
33 OHMS Full • 4/-2% 33-42 OHMS Ascending
900 OHMS Point B ± 5% N/A Descending
Transmission
temperature 114 OHMS 105.5 °C ± 3% 111-117 OHMS Ascending
(Red/green line) (Ref)
700 OHMS Point A ± 5% N/A Descending
Coolant
temperature 95 OHMS 110 °C ± 3% 93-97 OHMS (Ref) Ascending
(Red/green line)
11 V Left red/green line ± 3% 10.7-11.3 V (Ref) Descending
Volt
15.9 V Right red/green line ± 5% 15.0-15.6 V (Ref) Ascending
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 61

Other calibrations

INDICATOR READING RESISTANCE Ω

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Brake temperature 150 °C 30-45
Coolant temperature (buzzer) 112 °C 70-83
 Copyright ©

62 SECTION 55 - ELECTRICAL SYSTEM

AIR CONDITIONER KIT

1
3

87a
30

86
87
85
M
- +
10 11
9

Off

Off

Off
4
L M H

4
I H ML C

A S
12
5

X111 X110 S45

2 1 10 11

X111 X110 S45 X1

pos 8

+15 +30 +15

F27181

S Evaporator box S45 11 way connector

1 3RD speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Ventilated electrical motor 11 Thermostat
4 1 and 2 speed resistor 12 12 V light
5 Electrical cock A Waterproof 2 way connection
X111 9 way connector B Waterproof 5 way connection
X110 2 way power connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 63

PILOT LINE

TO SOLENOID
VALVES LINE
SAFETY
SWITCH
LVC RIGHT
JOYSTICK
LEFT
JOYSTICK
1 A B
X72 X23 X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 1 2
X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X20 X14 X14 X14 X14 X14 X14 X4 X4

N1
M-N1
G-R1

G-N1

M-B1
G-V1

B-G1

C-N1
A-R1
A-N1

B-R1
L-G1

V-N1
L-R1

Z-B1

V-B1
H1.5

N1.5

L-B1
H-G1.5

A1
L1
H-N1.5

K1 86 87a 87

85 30
N1

H-N1
H-R1.5

1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 1 2 1 2 A B A B 1 2
X13 X13 X13 X13 X13 X17 X17 YP4 YP4 YP3 YP3 YP6 YP6 YP5 YP5 YP7 YP7 YP8 YP8 XL XL XL XR XR XR X11 X11 X12 X12 X1 X1 X2 X2 X27 X27

CONNECTION
PRESS. SW
PRESS. SW
RETRACT
EXTEND
RH DOWN

JOYSTICK

PATTERN
JOYSTICK

PATTERN
LH DOWN

HORN JUMPER
RH STAB.

RH STAB.
LH STAB.

LH STAB.

VALVE 1

VALVE 2
PLUG 4

PLUG 3

PLUG 6

PLUG 5

PLUG 7

PLUG 8
MAINFOLD

RH UP
LH UP
POWER

P4

P3

P6

P5

P7

P8

R
L

2
B-R1
B-R1
H1.5

H-G1.5
H-N1.5

H-R1.5

N1

N1

N1
N1

1 2 3 4 5 6 1 2 1 2
X24 X24 X24 X24 X24 X24 YP9 YP9 YP10 YP10
AUX FORWARD
P10 PLUG 10
AUX REVERSE

LEFT
PLUG 9
N1

JOYSTICK
P9

2 5 3 6 7 8 2 3 7
S1 S1 S1 S1 S1 S1 S2 S2 S2

PILOT ON/OFF PATTERN

SWITCH SWITCH

31 31

F27182
 Copyright ©

64 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Safety relay
S1 Pilot on/off switch 8 way connector
S2 Pattern change switch 8 way connector
X1 Pattern valve “1” 2 way connector
X2 Pattern valve “2” 2 way connector
X4 Left joystick 2 way connector
Left stabilizer pressure switch 2 way
X11
connector
Right stabilizer pressure switch 2 way
X12
connector
X13 Right tower line 5 way connector
X14 Right joystick 6 way connector
X17 Manifold power 2 way connector
X20 LVC unit 23 way connector
X23 Safety switch 2 way connector
X24 Left stabilizer joystick 6 way connector
X27 Horn jumper connection 2 way connector
X72 Pilot control cable 1 way connector
XL Left stabilizer joystick 3 way connector
XR Right stabilizer joystick 3 way connector
YP3 Plug 3 left down 2 way connector
YP4 Plug 4 left up 2 way connector
YP5 Plug 5 right down 2 way connector
YP6 Plug 6 right up 2 way connector
YP7 Plug 7 extend 2 way connector
YP8 Plug 8 retract 2 way connector
YP9 Plug 9 reverse speed aux 2 way connector
YP10 Plug 10 forward 2 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 65

2.4 ELECTRICAL DIAGRAMS - ROPS

FUSES AND RELAIS DESCRIPTION

NAME DESCRIPTION
F1B Fuel shut off, antitheft power supply, grid heater (7.5 A)
K12

C1
F1C Stop lights switch (10 A)
K10 K11
Instruments power supply, brake oil level sensor, seat,
F2A
buzzer (15 A) K1

11
6

7
BZ1

XC2
XC1
F2C Pilot control (15 A)

D1

D5
D3
1

5
F3A Rear right/front left side lights, instruments illumination (3 A) K2
F1/C F2/C

7
D6
F3B Rear left/front right side lights, number plate light (3 A) D4

21
Front work light, tools rapid connection, Glide ride

11
F1/B F2/B

1
8
F3C
control, double delivery switches (10 A)

XC6
D2
Forward speed, reverse speed, reverse buzzer, speed F1/A F2/A

XC3
F4A
switch (5 A)
F3/C F4/C

13
Rear hammer button, grab level and sensor, clutch shut

7
F4B
off buttons (10 A) F3/B F4/B K3
Rear excavator lock, rear translation lock, rear work

12
1
F4C F3/A F4/A
light (10 A) K4

21
11
F5A Front inner work lights (15 A)

17
9
F5B Traffic lights (10 A)
F5/C K5
XC4
F5C Main beam (15 A)

XC5
F6A Beacon lamp (7.5 A) F5/B
K6
F6B (+15) Flasher (7.5 A) F5/A
12
1

10
1

F6C Hand hammer, 4WD (7.5 A) K7

F6/C F7/C F8/C
F7A (+30) flasher, (+30) antitheft, horn (10 A)
K8
F8A Outer rear work lights (15 A) F6/B F7/B F8/B
F8B Outer front work lights(15 A) F6/A F7/A F8/A K9
F8C Inner rear work lights (15 A) GND
1B020411
+15V

+30V
J1

J3
J2

F27195
 Copyright ©

66 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Forward-reverse speed switch relay
K12

C1
K2 Speed alarm, hand brake relay
K10 K11
K3 Starting relay
K1

11
6

7
K4 Grab level solenoid valve relay BZ1

XC2
XC1
K5 Traffic and main beam lights relay

D1

D5
D3
1

5
K2
K6 Inner front work lights relay
F1/C F2/C

7
D6
D4
K7 Inner rear work lights relay

21
11
F1/B F2/B

1
8
K8 Outer front work lights relay

XC6
D2
K9 Outer rear work lights relay F1/A F2/A

XC3
K10 Reverse speed relay
F3/C F4/C

13
K11 Forward speed relay

7
K12 Flasher F3/B F4/B K3

12
1
F3/A F4/A
K4

21
11

17
9
F5/C K5

XC4

XC5
F5/B
K6
12
F5/A
1

10
1 K7
F6/C F7/C F8/C
K8
F6/B F7/B F8/B

F6/A F7/A F8/A K9

GND
1B020411
+15V

+30V
J1

J3
J2

F27195
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 67

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION

BZ1 Alarm buzzer S3 Hand hammer switch (optional)
EV1 Double delivery solenoid valve (optional) S4 Double delivery switch (optional)
EV2 Hand hammer solenoid valve (optional) S5 Ride control switch (optional)
EV3 Rear hammer solenoid valve (optional) S6 Tools switch (optional)
EV4 Rear translation solenoid valve S7 Rear translation lock switch
Excavator rear lock solenoid valve S8 Excavator rear lock switch (optional)
EV5
(optional) S9 Lights switch
EV6 Grab level solenoid valve S10 Hazard
EV7 Fuel shut off solenoid valve S11 Front work light switch
EV8 4WD solenoid valve (optional) S12 Rear work light switch
EV9 Reverse speed solenoid valve S15 Beacon lamp switch
EV10 Forward speed solenoid valve S17 Starting switch
EV11 Ride control solenoid valve (optional) S18 Handbrake switch
EV12 Tools solenoid valve (optional) S20 Engine oil low pressure switch
EV24 Lifting solenoid valve S21 Air filter blocked switch
EV25 Lifting solenoid valve S24 Transmission oil pressure switch
FG1 General fuse 80 A S25 Transmission oil high temperature switch
FG2 A/C fuse (not connected) S26 Clutch shut off button
G1 Battery S27 Clutch shut off button
G2 Generator S28 Grab sender
H1 Excavator rear lock warning light (optional) S30 Rear hammer pedal button (optional)
H2 Front left light S31 Brake oil level sender
H3 Front right light S32 Stop light switch
H4 Rear left light S33 Stop light switch
H5 Number plate lamp S40 Gear shift
H6 Rear right light S41 Windshield wiper - lights switch
H11 Outer front left work light S42 Speedometer sender (optional)
H12 Outer front right work light S44 Seat (optional)
H13 Outer rear left work light S47 Main switch
H14 Outer rear right work light S48 Cold start temperature switch
H15 Beacon lamp S49 A/C pressure switch (not connected)
H16 Beacon lamp S52 Solenoid valves lock switch (optional)
H19 Inner front left work light (optional) S54 Rear horn button (optional)
H20 Inner front right work light (optional) ST2 Side multifunction panel
H21 Inner rear left work light (optional) General cable-engine cable 18 way
X1
H22 Inner rear right work light (optional) connector
HA1 Reverse speed buzzer X2 Cold start cable 6 way connector
HA2 Horn X3 Fuel shut off 1 way connector
K01 Starter relay X4 Air filter 2 way connector
K02 A/C relay (not connected) X6 Forward speed 2 way connector
K13 Antitheft unit X7 Reverse speed 2 way connector
KC Fuses-relays board General cable-rear lamps cable 12 way
X8
M1 Starter motor connector
M10 A/C compressor (not connected) General cable-front dashboard 17 way
X13
connector
R2 Engine water temperature sender
X14 Antitheft 11 way connector
R3 Fuel level sender
X15 Start switch 10 way connector
R4 Transmission oil temperature sender
X17 Seat 4 way connector
S2 4WD switch (optional)
 Copyright ©

68 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION

X21 Horn/left light 7 way connector Left side dashboard cable - general cable
X87
X22 Right light 5 way connector 13 way connector
X23 Clutch shut off button 2 way connector X89 Left lights 6 way connector
Rear translation lock solenoid valve 2 way X100 Right joystick 6 way connector
X24
connector XA Horn 2 way connector
Excavator rear lock solenoid valve 2 way XC1 On board 11 way connector
X25
connector XC2 On board 7 way connector
X26 Grab sender 3 way connector XC3 On board 21 way connector
X27 Pilot control horn button 2 way connector XC4 On board 21 way connector
X28 Clutch shut off button 2 way connector XC5 On board 17 way connector
X29 Grab level 2 way connector XC6 On board 13 way connector
Double delivery solenoid valve 2 way XD Fuel shut off diode 2 way connector
X30
connector XD1 Handbrake switch diode 2 way connector
Tools rapid connection solenoid valve 2 way X101 Right light 6 way connector
X31
connector
Solenoid valve lock switch kit 1 way
Rear hammer solenoid valve 2 way X104
X32 connector
connector
X124 Lifting solenoid valve 2 way connector
X34 Ride control solenoid valve 2 way connector
X125 Lifting solenoid valve 2 way connector
Hand hammer solenoid valve 2 way
X35 XST2 Side multifunction panel 36 way connector
connector
X36 Rear hammer button 2 way connector
X38 Rear right work light 4 way connector
Rear right work light (optional) 4 way
X40
connector
X41 Optional blower motor 2 way connector
X44 Front right work light 4 way connector
Front right work light (optional) 4 way
X45
connector
Rear left work light (optional) 4 way
X46
connector
X47 Rear left work light 4 way connector
Front left work light (optional) 4 way
X50
connector
X51 Front left work light 4 way connector
X61 Wiper and lights switch 12 way connector
X62 Gear shift 6 way connector
X63 Number plate light 2 way connector
X64 A/C compressor 1 way connector
X67 Generator 3 way connector
Engine water temperature switch and
X68
sender 3 way connector
X69 A/C pressure switch 2 way connector
X70 Front panel 12 way connector
X71 Starting switch 10 way connector
X72 Pilot control cable 1 way connector
X73 Engine oil pressure switch 1 way connector
X80 Beacon lamp 2 way connector
X81 Beacon lamp 2 way connector
X82 Controller 10 way connector
X83 Relay 2 way connector
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 69

ENGINE LINE

ST2
58 15/54 50
P0 12 15.5
25 18.6
30
12.4
20 21.7 MPH
35 km/h

S17
9.3
30 15
1 2
n/min
6.2
10
4

15.5/XXXLS

x1 000
0 3

5 6 2 8 1
X15 X15 X15 X15 X15 1 2 3 4 5 10 12 15 17 19 20 21 22 24 25 31 35 36
XST2

M1
G1
B1

S1

V1

G-R1

R-G1
Z1
R-N1

B-G1

G-V1

G/N1

C-N1
S-N1
B-V1

V-N1

Z-B1
C-N1 7.3
R-N1 8.1

B-V1 4.1
1 2 G/N1
XD1 XD1 8.2
G/R1

G/R1
16 7 S18
X13 X13

V1
H/R1 4.1
V1 4.1
G-R1 4.2
A2.5 5 2
A2.5 XC6 XC6

A2.5
+15
3
R6 2.5

+30

L-N1 2.1

1 2.3

K3 86 87a 87
2 4.3
H/R1
L-N1

B-N1.5
B-N1.5

L-N1.5

85 30

+15

1 2 3 4 5 6 7 8 9 10 11 F1B F2C
X14 7,5A 15A
N1.5

N1.5

K13

KC
6 13 3 10 9 7
XC6 XC6 XC6 XC6 XC6 XC6
H2.5
A2.5

G-V1.5 8.4
M1
R10

S1

B1

B-G1
S-N1
B/N1

L1.5

8
X1
1 11 13 12 9 16 7 GRID HEATER 1 10 15 2 14 5 3
G-V1.5

X1 X1 X1 X1 X1 X1 X1 X10 X1 X1 X1 X1 X1 X1
TO COLD
START KIT
R10

L-N1.5

B1

G-R1
Z1
B-G1
B-N1

V/N1

Z-B1
H2.5

B-N1
1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
K01 K02 1
86 87 86 87
X72

TO PILOT
85 30 85 30
CONTROL LINE
R2.5
V2.5
R4
R2.5

l
XD
V-N1

FG1 FG2
80A 10A
S1
S-N1

R16 -
V-B1

XD
L-N1
R25

R70 2 1 3
X67 X67 X67
G1 A B
B4

1 X68 X68
X64 1 1 A
12Vcc M1 2 M10 X3 X73 X4
30 50
S49
X69 G2 D+ EV7 S48 S20 S21
R2 R3
S24
R4
M M 30 G W
p 3 t p p p
N70

U
t t
S47 1 31
X69 B
C X4
N2.5

N1.5

X68
N1

N1

N1

N1

N1

N1

N1
N1
N70

31 2.1

F27479
 Copyright ©

70 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVES LINE

1 3 4 2 4 I II F N R NO
CB A A B I II F
0
R
S2 2
S3 3
S40 + + NI
M-V1
R-N1

1 2 3 4 5 6
X19
N1

M-B1
L/G1
C1 4.4
N1 4.3
R-N1 5.1

G/R1 7.1

10
X13

C1
M-N1
M-B1
M/B1

G/R1

H-N1

L/G1

7 2 6 11 5 9 3 1
XC4 XC2 XC2 XC4 XC1 XC1 XC1 XC1

1.4
3
F6C
7,5A
+15 +15

+15
F4B F4A
10A 5A

1.4
1

K1 86 87a 87
K4 86 87a 87
K10 86 87a 87
K11 86 87a 87
K2 86 87a 87

85 30 85 30 85 30 85 30 85 30

KC
5 1 6 9 19 16 8 8 1 11
XC3 XC3 XC3 XC3 XC3 XC3 XC3 XC6 XC6 XC3
L-N1

C1
1.1
L-N1 7.1
R-V1 R-V1 3.5
M-V1

C1
M-N1
M-B1
H-N1

A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

18 6 7 8 24 9 11 29 14 10 4 17 20
X1 X1 X10 X10 X10 X10 X10 X10 X10 X10 X1 X1 X10
M-B1

M-B1
H-N1

A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

M-N1
M-V1

C-N1
M-B1

M-B1
A-G1

H-R1
B-R1
A-R1

B-R1
A-R1

R-V1

2 1 1 2 1 2 1 2 C A B 1 2 1 2 2 1 2 2 1
X8 X8 X35 X35 X28 X28 X23 X23 X26 X26 X26 X29 X29 X7 X7 X19 X6 X6 X27 X27
EV2
EV8 S26 S27 S28 EV6 EV9 HA1 EV10 TO PILOT
1

CONTROL HORN
2

1
N2.5

N2.5

X19
N1

N1

N1
N1

N1

N1

N1

N1

1.5
31 31 3.1

F27480
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 71

SOLENOID VALVES LINE

C/B1 C/B1 6.2

C/N1
A B
2 4
A B
2 4
B A
1 3 4
A B
3 1 6 4
A B
2 4
B A
1 3
H1

S4 3
S5 3
S6 2 S52 2 5
S7 3
S8 2 4

N1
C/N1
A-N1
L-G1

C/N1
N1

N1 7.1
N1
C/N1 7.5
4.1

L/G1
C/N1

C-B1
V/B1

6 3 2 1 9 10
X13 X13 X13 X104 X87 X87
V1
A-N1

B-N1

C-B1
L-G1

L/G1
C/B1 6.1
M1

M1

2.5
R-V1

R-V1

23 16 27 18 17 15
X10 X10 X10 X10 X10 X10
R-V1

2
X36

S30
V1
A-N1

B-N1

C-B1
L-G1

1
X36
R-V1

1 2 1 2 2 1 1 2 1 2 1 2 1 2 1 2
X30 X30 X34 X34 X31 X31 X124 X124 X125 X125 X24 X24 X25 X25 X32 X32
EV5 EV3
EV1 EV12 EV24 EV25 EV4
EV11
1

1
N1

2
N1

N1

N1

N1

N1

N1

2.5
31 31 4.1

F27498
 Copyright ©

72 SECTION 55 - ELECTRICAL SYSTEM

LIGHTS LINE

3.5
N1 N1 6.1

1.4
G-R1

H/R1

G1.5
15/1 30/3 R/7 4 6 1 3
0 1 C BA

G-R1
S42 49/4 30b/2 49a/5 L/6
S9 5 2

H-L1
S31

A1
L1

H-N1.5

R2.5

R1.5
L-N1 7.1
A1 7.1
L1 7.1

6 5 4 3
X87 X87 X87 X87

1.1
H/R1 V-N1.5 7.1

1.5
B-V1
1.3
V1

12 14 8 13 11 4 15
X13 X13 X13 X13 X13 X13 X13

H-N1.5
V-N1.5
G-N1

H-R1

R/N1

H/R1
B-V1
G1.5

H-L1

L-N1

R2.5

R1.5
H1

3 18 6 21 10 10 9 3 8 16 20 5 4 2 4 13 2
XC2 XC4 XC4 XC4 XC1 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC4 XC1 XC4 XC5

+15 +30 +15

F6B F5B F5C F2A F7A
11 5.1 7,5A 10A 15A 15A 10A L1 5.1
10 5.1
A1 5.1
+15 +30

K12
F3B F3A + K5 86 87a 87
3A 3A L C
51 8.3
85 30
-

BZ1

KC 2 50
1.4 7.5
10
XC3

2.5
N1

2.5
C1
C1

H1

A1
H-N1
L1
H/R1

V-N1

6 7 1 4 5 2 3 1 4 5 2 3
X21 X22
G1
C1

N1
H1

H1
V1

V1
A1
G-N1
L1
H/R1

1 2
XA XA
C1

H-R1

1 2 3 5 4 1 2 3 5 4
X89 X89 X89 X89 X89 X101 X101 X101 X101 X101

H2 H3
HA2
R
L
56b

56a

58

56b

56a

58
31

31

3.5
31 31 5.1

F27482
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 73

REAR LIGHTS LINE

2.5
R-N1

S32 S33
4.5
L1

4.5
A1
R1
A1

R-N1
L1

B/R1
19 17 7 8 9 6 8 2 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC1 XC1 XC5

F1C
10A

+15

4.2
11

4.2
10 52 8.4

KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1

R-N1
L1

G1
A1
G-N1

G-N1
R-N1

R-N1
L1

5 2 6 4 3 9 8 10 7 1
X18
G1
N1

N1

N1
A1
G-N1

G-N1
R-N1

R-N1
L1

N1
G-N1

2 1
X63 X63
H4 H6
H5
59c

59c
R
L

58

58
31

31

N1

4.5
31 31 6.1

F27477
 Copyright ©

74 SECTION 55 - ELECTRICAL SYSTEM

WORK LIGHTS LINE

2.5
R-N1

S32 S33

4.5
L1

4.5
A1
R1
G1
A1

A1
G-N1

R-N1
R-N1
L1
L1

B/R1
19 17 7 8 9 6 8 2 7 17
XC4 XC4 XC5 XC5 XC5 XC5 XC1 XC1 XC1 XC5

F1C
10A

+15

4.2
11

4.2
10 52 8.3

KC
2 13 12 20 21
XC3 XC3 XC3 XC3 XC3
G1
A1

R-N1
L1

G1 8.3
G1
A1
G-N1

G-N1
R-N1

R-N1
L1

G1
N1

N1

N1

N1
A1

A1
G-N1
R-N1

R-N1
L1

L1

5 2 6 4 3 9 8 10 7 1 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
X8 X52 X48 X42 X37
G1
N1

N1

N1
A1
G-N1

G-N1
R-N1

R-N1
L1

N1
G-N1

2 1
X63 X63
H4 H6
H5
59c

59c
R
L

58

58
31

31

N1

N1

4.5
31 31 6.1

F27483
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SECTION 55 - ELECTRICAL SYSTEM 75

COLD START KIT

CONTROLLER

1 3 4 5 6 7 8 10
X82 X82 X82 X82 X82 X82 X82 X82

G1
R1

N1

M1

N1
S1
B-N1

V-B1
L-N1

1 2
X83 X83

1 2 3 4 5 6
X2 X2 X2 X2 X2 X2
GRID HEATER

RELAY
TO ENGINE LINE

F27176
 Copyright ©

76 SECTION 55 - ELECTRICAL SYSTEM

SIDE INSTRUMENT

Functional description

PIN NAME FUNCTION LAMP ID

No.
1 Ignition 10V-16V input
2 Low oil pressure Low side switch input LP1
3 Air filter restriction Low side switch input LP2
4 Park brake Low side switch input LP3
5 Alternator Alternator D input LP4
6 Not used
7 Crab steering Low side swtich input LP6
8 Neutral High side switch input
9 Seal switch Low side switch input
10 A/C system pressure High side switch input LP7
11 Not used
12 Driving beams High side switch input LP9
13 Not used
14 Not used
15 Engine pre-heat High side switch input LP12
16 Not used
17 Direction High side switch input LP14
18 Not used
19 Tachometer signal Alternator w input
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 77

20 Fuel sender Variable resistance input LP27

21 Transmission temperature sender Variable resistance input
22 Water temperature sender Variable resistance input
23 Not used
24 Driving lights High side switch input LP8
25 Brake High side switch input LP28
26 Not used
27 Not used
28 Not used
29 Not used
30 Not used
31 Trans oil pressure Low side switch input LP23
32 Not used
33 Front steering Low side switch input LP25
34 Circular steering Low side switch input LP26
35 Buzzer Open collector output
36 Ground Ground

Instrument calibrations
GAGE TYPE INPUT READING POINTER INPUT CALIBRATION
TOLERANCE TOLERANCE DIRECTION
0 Hz 0 rpm ± 3% N/A Descending
Tach 307 Hz 1000 rpm N/A ± 60 rpm Ascending
736 Hz 2400 rpm N/A ± 60 rpm Ascending
240 OHMS Empty • 0/-6% 230-240 OHMS Descending
(Ref)
Level fuel
102 OHMS 1/2 tank ± 3% (Ref) 98-108 OHMS Descending
33 OHMS Full • 4/-2% 33-42 OHMS Ascending
900 OHMS Point B ± 5% N/A Descending
Transmission
temperature 114 OHMS 105.5 °C ± 3% 111-117 OHMS Ascending
(Red/green line) (Ref)
700 OHMS Point A ± 5% N/A Descending
Coolant
temperature 95 OHMS 110 °C ± 3% 93-97 OHMS (Ref) Ascending
(Red/green line)
11 V Left red/green line ± 3% 10.7-11.3 V (Ref) Descending
Volt
15.9 V Right red/green line ± 5% 15.0-15.6 V (Ref) Ascending
 Copyright ©

78 SECTION 55 - ELECTRICAL SYSTEM

Other calibrations

INDICATOR READING RESISTANCE Ω

Low fuel (lamp) 1/10 Tank (Ref) 180-200
Brake temperature 150 °C 30-45
Coolant temperature (buzzer) 112 °C 70-83
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 79

OPTIONAL SEAT LINE

7.5
R-N1 1.5
G/N1
1.5
R-N1
R-N1
R-N1R-N1.5

G/N1
12 10 11 4
XC6 XC5 XC6 XC6
R-N1
N1

1 2 3 4
X17

S44

+30 +15

4.4
51 5.2
52

KC

7.5
31

F27499
 Copyright ©

80 SECTION 55 - ELECTRICAL SYSTEM

DIRECTION INDICATOR LIGHTS LINE

R-N1 8.1
6.5
C/N1

3.3
C/N1
N1

57/58 56b 56a 54S 54D 53 31b 49

H15 H16
0 12 R
5 0 2 4
A B A B M M
L
S41 56 30 L 15 31

S54 6
S15 3
C1

A-V1.5
1 2 3 4 5 6 7 8 9 10 11 12 - l - l
X61 X80 X80 X81 X81

V-N1.5

A1
G/R1

L1
A/N1
A/R1
A/B1

L-N1
3.5
N1
4.5
A1
L-N1 HA3
4.5
L1

A-G1.5
4.5
2.2
G/R1
4.5
V-N1.5

C-N1
N1

C/N1
6.5
N1

C/N1
L-B1

12 9 1.5
C-N1 5 1 2
X87 X13 X13 X13 X87
C1

C-N1

C/N1
C/N1
A-G1.5

A-G1.5
A-V1.5

Z1
Z1
N1

4 1 3 14 15 12 1 1 16 5 7 4 7
XC5 XC5 XC5 XC4 XC4 XC4 XC4 XC2 XC5 XC2 XC2 XC2 XC3

2.5
C1

F6A F3C
7,5A 10A

+15 +15 +15

+15

4.4
50
KC
17
XC3

5 6
X10 X10
N1.5
N1.5
N1.5
N1

6.5
31 31 8.1

F27500

SECTION 55 - ELECTRICAL SYSTEM
3. CONTROLS AND INSTRUMENTS
3.1 FRONT INSTRUMENT PANEL (580 Super R - 590 Super R)
1. 2/4 WHEEL DRIVE SWITCH
This switch is used to engage or disengage four
wheel drive.
The switch has three positions:
OFF = front axle drive disengaged, with braking
on all 4 wheels.
ON, 2nd position = the switch lamp goes out and
the front axle drive is disengaged (2WD).
ON, 3rd position = the switch lamp lights up and
the front axle drive is engaged (4WD).
NOTE: when the four wheel drive switch is in the
“OFF” position and both brake pedals are operated
together the four wheel drive, will automatically be
engaged (above 3 Km/h) to give four wheel drive
braking and disengage with brake pedals released.
2. HAND-HELD AUXILIARY HYDRAULIC TOOL
CONTROLS (Optional)
3. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch is for preventing any
movement of the loader attachment during trav-
el.
4. SWITCH FOR OPTIONAL EQUIPMENT
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
Copyright ©
81
6. HYDRAULIC SPEED CONTROL SWITCH
7. GLIDE RIDE SYSTEM CONTROL SWITCH
(Optional)
The glide ride system control improves the ma-
chine behaviour during travel, regardless of the
type of terrain and with the loader bucket full or
empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
carrying loads, at the same time increasing pro-
ductivity and operator comfort. It also minimises
impact forces to which the machine may be sub-
jected.
SWARNING
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
SWARNING
Never use the Ride Control system during handling
and loading operations, since this could damage the
accumulator.
 Copyright ©

82 SECTION 55 - ELECTRICAL SYSTEM

8. MANUAL MODE SELECTION SWITCH

(Powershift transmission)
In situations where a MANUAL gear change (up
or downshift) is required the powershift auto
change can be overridden by selection of this
console mounted switch.

NOTE: changing gears up or down must always be

done using the Powershift transmission lever.

When manual mode is no longer required, place the

control in “OFF” position to return to automatic gear
shifting.

9. WARNING HORN BUTTON (Powershift)

This hold-down switch operates the warning
horn.
10. HAZARD LIGHT SWITCH
Press the control down to locked position. The
direction indicators and the control will flash si-
multaneously.
Press down again for the direction indicators
and control lamp to go out.

SECTION 55 - ELECTRICAL SYSTEM
3.2 FRONT INSTRUMENT PANEL (695 Super R)
1. 2/4 WHEEL DRIVE SWITCH
This switch is used to engage or disengage four
wheel drive.
The switch has three positions:
OFF = front axle drive disengaged, with braking
on all 4 wheels.
ON, 2nd position = the switch lamp goes out and
the front axle drive is disengaged (2WD).
ON, 3rd position = the switch lamp lights up and
the front axle drive is engaged (4WD).
NOTE: when the four wheel drive switch is in the
“OFF” position and both brake pedals are operated
together the four wheel drive, will automatically be
engaged (above 3 Km/h) to give four wheel drive
braking and disengage with brake pedals released.
2. HAND-HELD AUXILIARY HYDRAULIC TOOL
CONTROLS (Optional)
3. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch is for preventing any
movement of the loader attachment during trav-
el.
4. STEER MODE SWITCH
This switch has a locking cover and is used to
select “Road”, “4WS” or “Crab steer”.
This switch has 3 positions:
Position (a) = “Road”
Position (b) = “4WS”
Position (c) = “Crab steer”
Copyright ©
83
IMPORTANT: before undertaking any road travel,
select “Road” mode and fold back the cover to lock
the switch in this position.
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
6. HYDRAULIC SPEED CONTROL SWITCH
7. GLIDE RIDE SYSTEM CONTROL SWITCH
(Optional)
The glide ride system control improves the ma-
chine behaviour during travel, regardless of the
type of terrain and with the loader bucket full or
empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
carrying loads, at the same time increasing pro-
ductivity and operator comfort. It also minimises
impact forces to which the machine may be sub-
jected.
SWARNING
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
 Copyright ©

84 SECTION 55 - ELECTRICAL SYSTEM

SWARNING
Never use the Glide ride system control during han-
dling and loading operations, since this could dam-
age the accumulator.

8. MANUAL MODE SELECTION SWITCH

(Powershift transmission)
In situations where a MANUAL gear change (up
or downshift) is required the powershift auto
change can be overridden by selection of this
console mounted switch.

NOTE: changing gears up or down must always be

done using the Powershift transmission lever.

When manual mode is no longer required, place the

control in “OFF” position to return to automatic gear
shifting.

9. WARNING HORN BUTTON (Powershift)

This hold-down switch operates the warning
horn.
10. HAZARD LIGHT SWITCH
Press the control down to locked position. The
direction indicators and the control will flash si-
multaneously.
Press down again for the direction indicators
and control lamp to go out.

SECTION 55 - ELECTRICAL SYSTEM
3.3 SIDE INSTRUMENT PANEL
1. FRONT WORK LIGHTS SWITCH
This switch has 3 positions:
1st position = “OFF”
2nd position = the two frontal outer working
lights turn on.
3rd position = the two front inner working lights
turn on.
The lights switch turns on only in the second and
third position.
2. LIGHT SWITCH
The switch has three positions:
- the first position is “OFF”,
- the second position powers the gauge cluster,
the parking lights, with heading indicator lamp
and the rear red lateral lights.
The third position powers the beam lights and
the main beam indicator lamp.
3. BACKHOE ATTACHMENT SIDESHIFT CAR-
RIAGE LOCKING AND UNLOCKING SWITCH
(Sideshift backhoe version)
This switch has 2 positions:
The switch is used to lock or unlock the backhoe
attachment sideshift carriage to allow lateral
shifting.
4. BACKHOE ATTACHMENT LOCKING SWITCH
(695 Super R)
This switch has 2 positions:
The switch is used to lock or unlock the backhoe
attachment locking plate in preparation for road
travel.
Copyright ©
85
5. REAR WORK LIGHTS SWITCH
This switch has 3 positions:
1st position = “OFF”
2nd position = the two rear outer working lights
turn on.
3rd position = the two rear inner working lights
turn on.
The lights switch turns on only in the second and
third position.
NOTE: never use the working lights during road
travel.
6. INSTRUMENT PANEL
7. REAR WINDSHIELD WIPER SWITCH
This switch is used to operate the windshield
wiper. It will continue to operate until the switch
returns to “OFF” position.
8. REAR WINDSHIELD WASHER SWITCH
The windshield washer will operate when this
switch is pressed and held down. When the
switch is released, the windshield washer ceas-
es to operate.
9. WARNING HORN BUTTON (Powershift)
This hold-down switch operates the warning
horn.
 Copyright ©

86 SECTION 55 - ELECTRICAL SYSTEM

INSTRUMENT PANEL

1. BRAKE LIQUID LEVEL WARNING LAMP 9. ENGINE OIL PRESSURE WARNING LAMP
This lamp comes on and the audible warning This warning lamp comes on and the audible
device sounds when the brake liquid is at mini- warning device sounds when the engine oil
mum level. pressure is too low. If the lamp comes on when
2. SIDE LIGHT AND DIPPED HEADLIGHT INDI- the machine is working, move the machine to a
CATOR LAMP place of safety, stop the engine, remove the
This indicator lamp lights up when the light starter switch key and find the cause of the prob-
switch is operated. lem.
3. MAIN BEAM INDICATOR LAMP 10. COLD START INDICATOR LAMP (If fitted)
This indicator lamp comes on when the main This lamp lights up while the engine is being
beam headlights are turned on. pre-heated.
4. DIRECTION INDICATOR LAMP 11. ALTERNATOR CHARGE WARNING LAMP
This lamp lights up when the direction indicators This warning lamp comes on when the alterna-
are working. tor/fan belt is broken or when the alternator is
5. AIR CONDITIONER INDICATOR LAMP (Op- not charging the battery. If the lamp comes on
tional) when the machine is working, move the ma-
This lamp comes on when the air conditioner is chine to a place of safety, stop the engine, re-
working. move the starter switch key and find the cause
6. “4WS” STEER INDICATOR LAMP of the problem.
(695 Super R) 12. PARKING BRAKE INDICATOR LAMP
This lamp comes on when four wheel steer This indicator lamp comes on when the parking
mode is selected and phased. brake lever is in the raised position (wheels
7. “ROAD” STEER INDICATOR LAMP braked).
(695 Super R) 13. AIR FILTER RESTRICTION WARNING LAMP
This lamp comes on when two wheel steer This warning lamp comes on when the air filter
mode is selected and phased. primary element is to be cleaned or replaced.
8. “CRAB” STEER INDICATOR LAMP 14. TRANSMISSION OIL PRESSURE WARNING
(695 Super R) LAMP
This lamp comes on when crab steer mode is This lamp lights up and the audible alarm
selected and phased. sounds when the transmission oil pressure is
too low. If the lamp comes on when the machine
is working, move the machine to a place of safe-
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 87

ty, stop the engine, remove the starter switch 21. ENGINE COOLANT SOLUTION TEMPERA-
key and find the cause of the problem. TURE INDICATOR
15. LOW FUEL LEVEL WARNING LAMP This indicator shows the temperature of the en-
This warning lamp comes on when the fuel level gine coolant solution. When the temperature is
is low. You have approximately an hour to fill the normal the needle is in the green area. If the
fuel tank. needle is in the red area the audible warning
sounds. Move the machine to a place of safety,
NOTE: when the starter switch key is in the “ON” po- stop the engine, remove the starter switch key
sition, lamps (9), (11), (12), (13) and (14) come on and check the coolant solution level. Make sure
for three seconds. After this time, only lamps (9), that the radiator and oil cooler are perfectly
(11) and (14) remain alight. clean and that all the thermostats function cor-
rectly.
16. BATTERY CHARGE INDICATOR
This indicator shows the state of charge of the
battery. At normal charge the needle should be
in the green area. If the needle is in the lower red
area, this shows that the battery charge is insuf-
ficient or that the alternator is not charging the
battery. If the needle is in the upper red area,
this indicates excessive battery charge which
may cause damage to the battery.
17. FUEL LEVEL GAUGE
This gauge shows the quantity of fuel in the fuel
tank.
18. HOURMETER
The hourmeter shows the hours and tenths of
hours for which the engine has been operated.
It also enables servicing operations to be sched-
uled.
19. ENGINE TACHOMETER / REVOLUTIONS
COUNTER
The tachometer shows the engine speed in rev-
olutions per minute.
The figures indicated must be multiplied by
1000.
Each intermediate mark shows a value of 100
rpm.
It is recommended not to exceed the green area
on the gauge.
The revolutions counter shows travel speed in
kilometres per hour (kmh) and miles per hour
(mph). Road speed in 4th gear with 18.4-26
tyres (19A).
20. TRANSMISSION OIL TEMPERATURE INDI-
CATOR
This indicator shows the transmission oil tem-
perature. When the temperature is normal, the
needle is in the green area. If the needle is in the
red area, change down to a lower gear. If the
needle still remains in the red area, stop the ma-
chine travel, place the gear change lever and
the direction of travel control lever in the neutral
position and leave the engine running at 1000
rpm. If this operation does not enable the oil
temperature to be reduced, check the gearbox
oil level and make sure that the radiator and oil
cooler are perfectly clean.
 Copyright ©

88 SECTION 55 - ELECTRICAL SYSTEM

3.4 DIAGNOSTIC SIGNALING

NOTE: for all machines fitted with diagnostic capa- OFF

LAPTOP
bility.
3
The reading of the diagnostics programming must
be done through the connector on the instrument
panel and with the display key in the off position and
NOT turned to the on +15 position.
When the connector with U screw is used the key ON
must be turned to the ON +15, any lamps and the 3
+15v
buzzer are turned off, but the cells recording the
times of events cannot be reset to zero.
The malfunctioning data for the functions being diag-
U F28664

nosed will be memorized on the micro processor

and can be displayed by the technician through a se-
rial line accessible through the 5 way 5238 Molex
connector (3).
The time of the malfunctioning of each individual
function will be memorized in four cells in the follow-
ing way.
The first malfunction will be memorized in the fourth
cell and will remain there until the user cancels it by
computer.
The next malfunction will be displayed in the first cell
and then slip into the second cell when the third mal-
function occurs until all 3 cells have been filled.
When the fifth malfunction occurs the data moves
down, cancelling the second occurrence and memo-
rizing the most recent one in the first cell.
In two way the very first and last three malfunctions
remain in the memory.
Each malfunction is memorized when it appears for
the first time at successive Key offs and Key on if the
same event occurs it will not be memorized as a new
malfunction.
The time will be memorized only if there has been a
rework of the service and a later anomaly.

NOTE: the data can only be cancelled while the

events are being visualized on the computer. There
may be a small variance between times shown on
the hour meter and those displayed by the diagnos-
tics programming.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 89

TOTAL HOURS

0.0 h

Engine oil Engine oil Transmission Engine cool

* Filter
pressure temperature oil pressure temperature
Last record 0h 0h 0h 0h 0h
Penultimate 0h 0h 0h 0h 0h
3rd record 0h 0h 0h 0h 0h

1st record 0h 0h 0h 0h 0h

SAVE ERROR
START MENU
Error Time
CANCEL
Out Out

MALFUNCTION EXAMPLE
* Filter

1st 2nd 3rd 4th 1st 2nd 3rd 4th

10 h 20 h 30 h 40 h
10 h
10 h 10 h
10 h 10 h 10 h

FUNCTION Check Service Diagnostic Note

Air filter Yes Yes
Transmission oil temperature Yes Yes
Transmission oil pressure Yes Yes
Engine coolant temperature Yes Yes
Service 1 Yes Yes
Battery Autocheck
Engine oil pressure Autocheck Yes
Engine cold start Autocheck Only on Iveco
Brake Yes
Buzzer Yes
 Copyright ©

90 SECTION 55 - ELECTRICAL SYSTEM

3.5 CALIBRATION OF SPEEDOMETER

Dependent upon the model and tyres fitted it may be

a requirement to set the calibration of the front con-
sole.
This setting is required if fitting a new instrument or
a change of tyres takes place, and can be performed
by adjusting the settings of the switch block, mount-
ed at the rear of the console.

Each switch numbered 1 to 8 mounted in the block

should be turned ON = or OFF as shown
in the opposite example, to suit the requirement and
8
as shown in the following tables.
7
Switch positions: 6
1 = ON 5
0 = OFF 4
3
2
on 1

F28666

POWERSHUTTLE

AXLE RATIO TYRE - ROLLING FREQUENCY AT SWITCH POSITIONS

CIRCUMFERENCE 50 Km/hr 1-2-3-4-5-6-7-8
18.5 4065 - 4335 2055 1-1-1-1-0-1-0-0
18.5 3810 - 3911 2245 1-1-1-0-1-0-1-0
20.8 4065 - 4335 2310 1-1-1-0-1-1-1-0
20.8 3810 - 3911 2522 1-1-0-0-0-0-0-1

POWERSHIFT

EGS FREQUENCY TYRE - ROLLING FREQUENCY AT SWITCH POSITIONS

CIRCUMFERENCE 50 Km/hr 1-2-3-4-5-6-7-8
6.53 - 6.12 4065 - 4335 315 Hz 0-0-0-0-0-0-0-0
6.97 - 6.79 3810 - 3911 345 Hz 0-1-0-0-0-1-0-0
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 91

3.6 IMMOBILISER CIRCUIT

F28667

A. M38 Immobiliser E. Starter motor

B. Electronic key socket with LED F. + 15 key positive
C. 2 piece electronic key G. Electronic key
D. + 50 to ignition

Wire Function Connection

No.
1 (+15) Key positive
2 (+30) Permanent + 12 V power supply
3 (-31) Negative power supply
5-6 Immobilization relay No. 2
7 - 8 - 9 Immobilization relay No. 1
Connected to the + 12 V full ignition supply
Connected to the wire from the battery positive
Connected to the vehicle negative at two independent
points
Connected in line with the wire controlling the starter
motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
Connect in line with the wire controlling the ignition or
fuel circuit - Minimum 500 mA maximum 10 A capacity
 Copyright ©

92 SECTION 55 - ELECTRICAL SYSTEM

4. STARTING SYSTEM
4.1 DESCRIPTION AND OPERATION

The system includes a key switch, reinforced ca-

bling, a motor and a relay and solenoid assembly.
This is a starter motor with built-in solenoid and pos-
itive engagement drive system.
When the key switch is operated with the forward
and reverse travel lever in the neutral position, the
solenoid windings are energized and cause the mo-
bile core to be drawn inside the solenoid.
This movement causes the drive pinion to mesh with
the ring gear on the engine flywheel. When the ring
gear and the drive pinion are engaged, the mobile
core of the solenoid closes a series of contacts ena-
bling the battery to power the field coils directly and
provide the entire power to the starter motor.
The starter motor contains only a single set of con-
tacts and a mobile core, which closes the contacts
completely, even if the teeth of the drive pinion and
the gear are not aligned. In this case, a spring is
compressed and forces the complete engagement of
the pinion as soon as the starter motor starts rotat-
ing.
Once the ignition is turned off, the solenoid and the
starter motor are de-energized. The solenoid’s recoil
spring causes the drive pinion to be uncoupled and
the contacts of the solenoid to reopen.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 93

4.2 FAULT FINDING

The motor does not start if the ignition key is operated and the transmission is in the neutral position.

Is the battery properly charged? NO Charge or replace the battery

YES
Check the starter motor cabling. Are there bad Repair or replace the cables
connections, cut or stripped cables? YES

NO
Is the starter motor seized? YES Repair or replace the starter motor
NO
Operate the key switch. Is there a Does the solenoid Windings, brush or starter
voltage of +12 V on the (white) wire at make a “clicking” YES motor mechanism possibly
the input of the starter motor solenoid YES
sound? defective.
(terminal 30)?
NO
NO

Check the starter motor relay (K01). Solenoid possibly

Can one hear the relay operate after defective. Remove the
operating the key switch? starter motor and inspect
NO

Remove the connector from the relay (K01). Is there a voltage of

+12 V at terminal 86 (white/black) after the key switch is YES Replace the relay
operated?
NO

Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO

Remove the connector from relay K3. Is there a voltage of +12 V

YES Replace the relay
at terminal 86 (white/black) after the reverse travel lever is
NO
Are the cable wires of the reverse travel lever properly Reconnect the wires to the
NO
connected? switch
YES
Does the reverse travel lever switch operate correctly? NO Replace the switch
YES
Check the main power
Are the indicators on the instrument panel correctly lighted supply between the battery
after operating the key switch? NO
and the starter motor key
YES switch. Pin 2 (red wire) of
the ignition key connector.
Are the cable wires of the key switch connected correctly?
YES NO

Replace the key switch. Reconnect the wires to the key

switch
 Copyright ©

94 SECTION 55 - ELECTRICAL SYSTEM

CHECKING THE STARTER MOTOR CIRCUIT

To troubleshoot the starter motor circuit rapidly and
easily, it is recommended that a battery-starter motor
testing device (quick discharge) be used, which in-
cludes a 0-20 V voltmeter and a 0-500 A ammeter to
detect problems in the starter motor circuit.
Use a testing device in accordance with the manu-
facturer’s instructions. If a testing device of the type
indicated is not available, use a standard 0-20 V volt-
meter and a 0-500 A ammeter to check the operation
of the starter motor on the vehicle.
Before testing:
Z Check that the battery is properly charged.
Z Check the state of the starter motor circuit, by mak-
ing sure that no wire is cut or stripped and that the
connections are not loose.
Z Check that the motor is not seized.

Current draw of the starter motor circuit:

1. Disconnect the ground cable (negative) from the
battery (3).
2. Disconnect the positive cable from the battery on
the solenoid of the starter motor. Connect the
positive cable of the ammeter (1) to the positive
terminal of the battery and the negative cable to
the input terminal of the solenoid.
3. Reconnect the ground cable (negative) of the
battery to the negative terminal of the battery.
4. Connect the positive cable of the voltmeter (2) to
the positive terminal of the battery and the neg-
ative cable of the voltmeter to the negative termi-
nal of the battery.
5. Disconnect the injection pump fuel inlet cut-off
wire from the solenoid.
6. Start the motor and observe the values indicated
by the voltmeter and ammeter. The voltage must
remain steady at around 12 V with a current
draw of 250 to 300 A.
Z If the current draw is within the indicated range, the
starter motor (4) is operating correctly. If the voltage
reduces during the test, refer to the “Resistance of
the starter motor circuit” section below.
Z If the current draw is higher than the specified
range, check the circuit as indicated below. If tests
of the starter motor circuit have proved satisfactory,
the starter motor is defective and must be removed
in order to identify the source of the problem.
Z If the current draw is less than the specified range,
the starter motor is defective and must be removed
in order to identify the source of the problem.
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SECTION 55 - ELECTRICAL SYSTEM 95

RESISTANCE OF THE STARTER MOTOR

CIRCUIT
(Voltage lowering)
If the current draw is excessive, check the circuit by
noting down the voltage lowers at various compo-
nents of the circuit.

IMPORTANT: disconnect the injection pump fuel in-

let cut-off wire from the solenoid.

Positive cable of the battery:

1. Connect the positive cable of the voltmeter (1) to
the positive terminal of the battery (2).
2. Connect the negative terminal of the voltmeter
(1) to the terminal connected to the battery of the
starter motor solenoid (3).
3. Start the starter motor and observe the reading
on the voltmeter. If the voltage lower is greater
than 0.2 V, check and retighten the cable con-
nections. Check the voltage again. If it is still ex-
cessive, replace the cable.

Connections to the starter motor ground:

1. Connect the positive cable of the voltmeter (1) to
the body of the starter motor (2).
2. Connect the negative cable of the voltmeter (1)
to the motor block (3).
3. Start the starter motor and observe the reading
on the voltmeter. If the voltage lower is greater
than 0.2 V, check and retighten the cable con-
nections, check the ground connections be-
tween the starter motor clamp and the
undercarriage.

Ground cable of the battery:

1. Connect the positive cable of the voltmeter (1) to
the motor block (2).
2. Connect the negative cable of the voltmeter (1)
to the negative terminal of the battery (3).
3. Start the starter motor and observe the reading
on the voltmeter. If the voltage lower is greater
than 0.2 V, check and retighten the ground cable
connections. Check the voltage again. If it is still
excessive, replace the ground cable.
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96 SECTION 55 - ELECTRICAL SYSTEM

4.3 STARTER MOTOR

TECHNICAL SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Voltage ......................................................................................................................................................... 12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ....................................................................................................................................................... 8.4 kg
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm at 8 V and 1130 rpm minimum ................... 600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm minimum ............... 1400 A maximum

MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
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SECTION 55 - ELECTRICAL SYSTEM 97

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98 SECTION 55 - ELECTRICAL SYSTEM

1. Washer
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Brush bracket
10. Protective cover
11. Screw and washer
12. Screw
13. Ventilation drain of the rear hood
14. Screw and washer
15. Solenoid hood
16. Union
17. Spring washer
18. Nut
19. Push-rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Retaining ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Flat washer
33. O-ring
34. Box
35. Pinion, rings and spring assembly
36. Union
37. Bearing
38. Bearing
39. Spring
40. Shaft pinion
41. Solenoid housing
42. Clutch assembly
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SECTION 55 - ELECTRICAL SYSTEM 99

REMOVING AND INSTALLING THE STARTER

MOTOR
Z Disconnect the ground cable (negative) from the
battery.
Z Remove the rear protective cover and disconnect
all cables connected to the starter motor.
Z Remove the three retaining screws of the starter
motor and remove the starter motor.
Z To install the starter motor, proceed in the reverse
order to that of removal.

TEST BENCH CHECK

Checking the starter motor without load

NOTE: before carrying out the test, check that the

battery is fully charged then obtain a battery-starter
motor testing device (quick discharge) and a carbon
cell (variable load resistance).

Z Lock the starter motor in a vice with soft jaws.

Z Connect the negative cable (4) of the battery to the
mounting clip of the starter motor.
Z Connect a short cable (6) between the solenoid
battery wire and the terminals of the solenoid
switch.
Z Connect the positive cable of the voltmeter (3) to
the positive terminal of the battery, the negative ca-
ble of the voltmeter to the negative terminal of the
battery, the positive cable of the ammeter (1) to the
positive terminal of the battery and the negative ter-
minal of the ammeter to the terminal of the battery
or the starter motor.
Z Install a tachometer (5) at the end of the armature
shaft. Activate the starter motor by adjusting the
carbon cell (2) to obtain a voltage of 11 V. When
the armature is rotating at 3000 rpm, the maximum
current draw must not exceed 200 A.
Z If the starter motor does not fulfil these conditions,
check that the field coils are not grounded, that the
armature is not rubbing and that its shaft is not de-
formed.
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100 SECTION 55 - ELECTRICAL SYSTEM

Armature
Z The surface of the commutator must be clean and
without traces of burns. If necessary, remove trac-
es of burns using fine sandpaper. Do not use em-
ery cloth. Then, clean the commutator with a cloth
soaked in gasoline.
Z After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in
gasoline.

NOTE: make sure not to graze the metal of the com-

mutator during rectification of insulating notches.

Z The resistance of the armature insulation may be

checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no conti-
nuity).
Z To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
Z If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the arma-
ture bearings.

Field coils
Z To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
Z To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
Z If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.

Drive pinion
Z The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive as-
sembly.

NOTE: if the teeth of the drive pinion are damaged,

also check the teeth of the engine flywheel ring gear.

SECTION 55 - ELECTRICAL SYSTEM
FAULT FINDING
PROBLEM
Starter does not rotate (magnetic
switch does not make an
operating noise)
Starter does not rotate (magnetic Poor battery specific gravity and
switch makes an operating noise) level
Starter rotation is slow
Starter rotation cannot crank the
engine
Abnormal noise
Pinion gear springing out
Field coil loss
Magnetic switch coil burn, etc.
CAUSE
Poor battery specific gravity and
level
Poor ignition switch circuit
connection or contact
Malfunction of the magnetic
switch pull-in coil or plunger
Poor start-up circuit contact
Poor contact of magnetic switch
contact
Motor assembly malfunction (e.g.
layer short, brush wear)
Poor contact of magnetic switch
contact
Motor assembly malfunction (e.g.
layer short, brush wear)
Pinion gear does not engage with
ring gear
Clutch sliding
Abnormal bushing wear
Wear on pinion gear or ring gear
teeth tips
Poor pinion gear sliding
Poor ignition switch return
Pinion gear disengagement fault
caused by a coil layer short in the
magnetic switch
Copyright ©
101
ACTION
Inspect battery.
Replace wiring and ignition switch.
Replace magnetic switch.
Inspect battery.
Repair wiring.
Replace magnetic switch.
Repair or replace motor assembly.
Replace magnetic switch.
Repair or replace motor assembly.
Repair or replace the clutch and
drive lever.
Replace clutch.
Replace bushing.
Replace clutch and ring gear.
Lubricate or replace clutch.
Replace ignition switch.
Replace magnetic switch.
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102 SECTION 55 - ELECTRICAL SYSTEM

5. ALTERNATOR
5.1 TECHNICAL SPECIFICATIONS

Manufacturer .............................................................................................................................................Denso
Rated voltage ............................................................................................................................................... 12 V
Polarity .................................................................................................................... Negative terminal grounded
Current ........................................................................................................................................................ 90 A
Minimum charging speed ..................................................................................................................... 1400 rpm
Maximum speed................................................................................................................................... 9000 rpm
Operating temperature ................................................................................................................ -30 °C to 90 °C
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 °C .........................................................................14.2 - 14.8 V
Maximum load that can be applied at terminal L.........................................................................12 V, 3.4 W x 6

5.2 DESCRIPTION AND OPERATION

The alternator, installed on the motor, on the front

RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt. The alternator contains
built-in regulators.

Current draw of the starter motor circuit:

When the ignition key is turned, a current of low in-
tensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) comes
on and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alter-
nating current is generated (terminal B+). A constant
1. Ground connection
portion of this current is transformed into a direct cur-
2. Terminal P: motor tachometer
rent by three excitation diodes installed in the rectifi-
3. Terminal L: charge indicator
er.
4. Terminal B+: charge +12 V
The direct current is sent as reinforcement through
5. Terminal IG: +12 V after ignition (10 A fuse)
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases when
the voltage generated at the output is increasing (ter-
minal L). The indicator lamp goes out when the volt-
age at terminal “L” is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage does
not accumulate in the alternator and the load indica-
tor lamp remains lighted to indicate the problem.
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SECTION 55 - ELECTRICAL SYSTEM 103

DIAGRAM OF THE CHARGING CIRCUIT

1. Alternator
2. Output winding of the rotor
3. Rectifier
4. Regulator
5. Starter motor
6. Battery
7. Key switch
8. Charge indicator
9. Tachometer
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104 SECTION 55 - ELECTRICAL SYSTEM

5.3 COMPONENTS

1. Front housing 16. Seal ring

2. Rear housing 17. Seal ring
3. Rectifier 18. Washer
4. Brush holder 19. Screw
5. Regulator 20. Electrical terminal
6. Rear protective 21. Screw
7. Insulation ring 22. Bearing
8. Insulation ring 23. Flange
9. Screw 24. Flange
10. Screw 25. Stator
11. Nut 26. Stud screw
12. Nut 27. Bearing
13. Rotor 28. Plate
14. Pulley 29. Screw
15. Pulley nut
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 105

5.4 REMOVAL

Electrical disconnections of the alternator

1. Disconnect the negative cable from the battery.
2. Disconnect the battery cable (1) from terminal
B+ (2).
3. Disconnect the connector (3).

Removing the alternator

1. Free the tension roller (1) using a suitable
wrench, then remove the belt (2).
2. Remove the screw (3) and the nut (4).
3. Remove the screw (5).
4. Remove the alternator.
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106 SECTION 55 - ELECTRICAL SYSTEM

5.5 PRELIMINARY CHECK AND TESTS

To prevent damage to components of the alternator

charging circuit, the following precautions must be
taken during maintenance:
Z NEVER connect or disconnect a charging circuit
connection, including the battery, when the motor is
running.
Z NEVER dead short to ground any component of the
charging circuit.
Z ALWAYS disconnect the ground cable from the
battery (negative) to recharge the battery on the ve-
hicle using a battery charger.
Z ALWAYS respect the polarity when connecting the
battery on the vehicle or when connecting an auxil-
iary starter battery to the motor.

IMPORTANT: connect the positive cable to the pos-

itive terminal and the negative cable to the negative
terminal.

PRELIMINARY CHECKS
Before undertaking an electrical inspection, check
the charging circuit and the electrical circuit carefully.
Check the state of cables and the tightening of con-
nections.

Checking the battery

Check each cell of the battery with a hydrometer.
The battery must be charged at least 70% and be in
good condition.

Checking the drive belt

Check that the belt and the pulley of the alternator
are clean, without any trace of oil and grease and
that they are in good condition.

Checking the indicator lamp

Turn the ignition key and check that the charge indi-
cator is well lit.
If it is not fully lighted, check its bulb. If the bulb is OK,
check the alternator wire connections as described
in the “Preliminary tests” section below.
If the indicator lamp is lighted, start the motor and run
it at a speed that is higher than the idling speed. The
indicator lamp must go out.
If the indicator lamp does not go out, turn off the mo-
tor and disconnect the ground cable L. If the indicator
lamp goes out, an alternator component is defective.
Follow the instructions given in the “Checking the al-
ternator components” section below.
If the indicator lamp stays lighted, look for a dead
short to ground between the terminal “L” cable and
the indicator lamp.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 107

PRELIMINARY TESTS
The preliminary tests may be carried out without re-
moving the charging circuit components, these tests
help check the following items:
Z Connections of the alternator cables
Z Charging current and regulated voltage of the alter-
nator
Z Voltage lowers in the alternator charging circuit
Z Maximum flow of the alternator

Required devices:
Z Voltmeter (0-30 V, moving coil)
Z Millivoltmeter (0-1 V)
Z Ammeter (0-110 A, moving coil)
Z Variable resistance of 1.5 Ohm, 110 A

NOTE: most testing instruments sold in shops group

together several measurement functions in a single
device. Use these devices in accordance with the
manufacturer’s instructions.

CHECKING THE CONNECTIONS OF THE

ALTERNATOR CABLES
Z Disconnect the battery.
Z Disconnect the terminals B+ (2) and L (3) from the
alternator.
Z Reconnect the battery and turn the ignition key
without starting the motor. Connect a voltmeter (4)
between each terminal (B+ or L) and the ground
(1). The voltmeter must show the battery voltage.
Z If there is no battery voltage, the external cable has
a continuity fault; in this case, check the entire cir-
cuit and carry out the necessary repairs.
Z Connect the terminal L indicator lamp wire to the
ground. The indicator lamp should come on.
Z Disconnect the battery and reconnect the cables to
the alternator.

NOTE: if the indicator lamp does not come on after

having reconnected the alternator, the regulator of
the alternator or the rotor circuits is defective. Make
sure that terminal L is clean, then check the compo-
nents of the alternator as indicated in this chapter.
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108 SECTION 55 - ELECTRICAL SYSTEM

CHECKING THE CHARGING CURRENT AND

THE REGULATED VOLTAGE
Z Make sure that all electrical components are pow-
ered off and that the ignition is turned off (key on
“off”).
Z Disconnect the negative terminal from the battery
and disconnect terminal B+ (4) from the alternator.
Z Connect an ammeter (1) between the disconnect-
ed cable (3) and terminal B+ of the alternator.
Z Connect a voltmeter (2) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery. Start the motor and run it at
a speed of 2000 rpm. Observe the values shown
on the ammeter and the voltmeter.
The voltage shown on the voltmeter should at first be
too high and then should stabilize between 14.2-
14.8 V when the value on the ammeter lowers below
10 A.
If the voltmeter stabilizes at a voltage greater than
14.8 V, the regulator of the alternator needs to be re-
placed.
On the other hand, if the voltmeter stabilizes below
14.2 V, a component of the alternator is defective or
the resistance in the external connections of the
charging circuit is too high.
If the ammeter indicates zero amps, an alternator
component is defective.
Turn off the motor and carry out the operations de-
scribed in the “Checking the alternator components”.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 109

CHECK THE VOLTAGE LOWERINGS IN THE

CHARGING CIRCUIT

Voltage lowers on insulated side

Check that the ignition is turned off (key on “off”).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (1) from the alternator.
Z Connect a millivoltmeter (4) between the positive
terminal of the battery and cable B+ (5) (positive
side on cable).
Z Connect an ammeter (2) between terminal B+ of
the alternator and cable B+ (negative side on ca-
ble).
Z Reconnect the negative cable of the battery and
connect a variable resistance (3) between the bat-
tery terminals by adjusting the cursor to the mini-
mum current draw (maximum resistance).
Z Start the motor and increase its speed to 2000 rpm.
Z Gradually reduce the resistance until the ammeter
shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 400 millivolts.
If the value exceeds 400 millivolts, the resistance of
the external circuit is too high. If the output value of
the alternator is not sufficient and the millivoltmeter
indicates a value that is less than 400 millivolts, an
alternator component is defective. Carry out the op-
erations described in the “Checking the alternator
components”.
Z Switch off the motor.

Voltage lower on ground side

Z Check that the ignition is turned off (key on “off”).
Z Check the same circuit as the one in the previous
test, but by connecting the millivoltmeter (4) be-
tween the negative terminal of the battery and the
alternator body (negative side on body).

NOTE: make sure that the variable resistance (3) is

in the minimum current draw position (maximum re-
sistance).

Z Start the motor and increase its speed to 2000 rpm.

Z Gradually reduce the resistance until the ammeter
(2) shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 200 millivolts.
If the value exceeds 200 millivolts, the resistance of
the external circuit is too high.
If the output value of the alternator is not sufficient
and the millivoltmeter indicates a value that is less
than 200 millivolts, an alternator component is defec-
tive. Carry out the operations described in the
“Checking the alternator components”.
Z Switch off the motor.
 Copyright ©

110 SECTION 55 - ELECTRICAL SYSTEM

CHECKING THE MAXIMUM OUTPUT OF THE

ALTERNATOR
Z Make sure that the ignition is turned off (key on
“off”).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (5) from the alternator.
Z Connect an ammeter (2) between terminal B+ (1)
of the alternator and the disconnected cable B+
(negative side towards the cable).
Z Connect a voltmeter (4) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery, start the motor and in-
crease its speed to 2000 rpm.
Z Gradually reduce the resistance (3) until the am-
meter shows 90 A.
Z Observe the voltmeter, which must not indicate a
value that is less than 14.2 V.
If the value lowers below 14.2 V, an alternator com-
ponent is defective.
Carry out the operations described in the “Checking
the alternator components”.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 111

CHECKING THE ALTERNATOR COMPONENTS

Checking of components must be done only if the
PRELIMINARY TESTS reveal an alternator defect
which relates to the following components:
Z Regulator
Z Continuity of the rotor field winding
Z Brushes, springs and slip rings

NOTE: these checks may be carried out without re-

moving the alternator from the vehicle.
The alternator must be removed to check the other
components of the alternator.
Refer to the “Removal” section in this chapter.

IMPORTANT: before disconnecting the cables from

the alternator, make sure that the ignition is turned
off (key on “off”) and the negative cable of the battery
is disconnected.

Required devices:
Z 12 V battery
Z Multimeter
Z 2.2 W test lamp

CHECKING THE REGULATOR AND THE FIELD

CIRCUIT OF THE REGULATOR
Z Disconnect all cables from the alternator.
Z Connect a 12 V battery and a 2.2 W test lamp (2) in
series between terminal L (1) and the alternator
body (negative side on body).
Z The test lamp must come on.
If the lamp does not come on, the rotor circuit is de-
fective. Check the brushes, the slip rings and the
continuity of the rotor field windings.
If the inspection reveals that these components are
in good condition, the defect may be due to the reg-
ulator.
CHECKING THE CONTINUITY OF THE ROTOR
FIELD WINDING

Z Remove the regulator with the brush holder.

Z Connect an ohmmeter (3) between the slip rings
(2). The resistance must be 2.6 ohms at 20 °C.
If the resistance is not correct, replace the rotor (1)
as described in the “Removal” section below.
 Copyright ©

112 SECTION 55 - ELECTRICAL SYSTEM

RECTIFIER - CHECKING THE POSITIVE /

NEGATIVE DIODES
Check each of the six diodes separately by proceed-
ing as follows:
Z Connect a multimeter (2) in series with one of the
diodes. Place one wire of the multimeter on the
connecting pin (1) of the diode and the other wire
on the plate where the diode is installed.
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multime-
ter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.

RECTIFIER - CHECKING THE EXCITATION

DIODES
Check each excitation diode separately by proceed-
ing as follows:
Z Connect a multimeter (2) in series on the excitation
diode module. Place the negative wire on terminal
L (1) and the other wire on the connection of each
excitation diode (3).
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multime-
ter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.
STATOR - CHECKING THE CONTINUITY OF THE
WINDING
Check each excitation diode separately by proceed-
ing as follows:
Z Connect the wires of the ohmmeter (3) between
wires A, B and C (2). The resistance between each
of the wires must be low (0.1 W). If the resistance
is greater than this value, it indicates a possible
break in the winding, i.e. an open circuit. A lower
value (0.0. for example) indicates a short circuit in
the winding. If the result of this check is not satis-
factory, replace the stator (1) and its casing.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 113

STATOR -CHECKING THE INSULATION

Z Check the insulation of each winding with respect
to the alternator casing. There must not be any
continuity between the winding and the casing. If
the ohmmeter (2) indicates any value other than an
open circuit, replace the entire stator (1).

CHECKING THE ROTOR

Before checking the rotor components, inspect the
slip rings to make sure that they are in good condi-
tion.
Z Check that the slip rings are clean and smooth. If
necessary, clean them with a cloth soaked in gaso-
line. If the slip rings are burnt, scrape them with
very fine sandpaper (do not use emery cloth) and
wipe them.

NOTE: make sure that the sandpaper is sufficiently

fine in order to obtain a perfect finish of the slip ring
surfaces and avoid premature wear of the brushes.

Z If the slip rings are excessively worn, replace the

rotor.
ROTOR - CHECKING THE CONTINUITY OF THE
FIELD WINDING
Z Connect an ohmmeter (3) between the two slip
rings (2). The resistance must be 2.6 ohms at 20
°C.
If the resistance is incorrect, replace the rotor (1).
 Copyright ©

114 SECTION 55 - ELECTRICAL SYSTEM

ROTOR - CHECKING THE INSULATION OF THE

FIELD WINDING
Z Using an ohmmeter (3), measure the resistance
between each slip ring (2) and the rotor terminals
(1). The resistance should always be infinite. If a re-
sistance is not infinite, replace the rotor.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 115

5.6 FAULT FINDING

PROBLEM CAUSE ACTION

Not recharged Recharge circuit cut out (warning Check the connections of recharge
light, fuse, connector, etc. circuit, clean and tighten the
alternator and battery tags.

Voltage regulator inefficient Replace the part.

Rotor winding cut out Replace the part.

Worn brushes Replace the part.

Recharge insufficient Slackened fan belt Supply correct voltage.

Voltage regulator faulty Replace the part.

Excessive wear of rotor rings or Replace the part.

brushes

Diodes short-circuited Replace the part.

Stator windings or rotor winding Replace the part.

short-circuited
Excessive recharge Circuit connections loosen Check the connections of battery
terminals and tag blocks starter and
alternator.

Replace the part.

Voltage regulator inefficient

Ground connection fault Check connections for leakages.

 Copyright ©

116 SECTION 55 - ELECTRICAL SYSTEM

6. BATTERY
For the loader backhoe models two different kinds of installation are provided:
Z with one battery.
Z with two batteries (for harsh climates).

6.1 TECHNICAL SPECIFICATIONS

Single battery
Voltage: ........................................................................................................................................................ 12 V
Capacity (20 h):..........................................................................................................................................95 Ah
Discharge current:...................................................................................................................................... 900 A
Weight with electrolyte: .............................................................................................................................. 25 kg

Double battery
Voltage: ........................................................................................................................................................ 12 V
Capacity (20 h):..........................................................................................................................................60 Ah
Discharge current:...................................................................................................................................... 600 A
Weight with electrolyte: .............................................................................................................................. 17 kg

6.2 DESCRIPTION AND OPERATION

All models feature one or two 12 volt, negative

ground, “maintenance free” lead calcium (Pb-Ca)
type battery, of six cell construction.

IMPORTANT: “Maintenance Free” means that un-

der normal charging conditions the battery does not
lose water from the electrolyte. Conditions that may
cause water loss include prolonged charging above
14.4volts where gassing occurs as it approaches full
charge. This can be caused by a faulty charging sys-
tem or boost/recovery charging equipment.

The battery has four major functions:

Z To provide a source of current for starting, lighting
and instrumentation.
Z To help control the voltage in the electrical system.
Z To furnish current when the electrical demands ex-
ceed the alternator output.
Z To support quiescent loads from radio and micro
processor memory.
The battery is constructed in such a manner that
each cell contains positive and negative plates
placed alternatively next to each other. Each positive
plate is separated from a negative plate by a non
conducting porous envelope separator. If any of the
positive plates should make contact with negative
plates within a cell, the cell will short circuit and suffer
irreparable damage. All of the positive plates are
welded to a bus-bar, forming a positive terminal and
all of the negative plates are welded to a similar bus-
bar forming a negative terminal.
Each positive plate is composed of a lead grid with
lead peroxide pasted into the grid openings.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 117

The negative plates are composed of a lead grid with

spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte so-
lution of diluted sulphuric acid.

6.3 BATTERY REPLACEMENT

Use the ignition switch key to open the battery box

and then remove the tool box.

SWARNING
A spark or flame can cause the hydrogen in a battery
to explode. To prevent any risk of explosion, observe
the following instructions:
Z Place the battery master switch key in the OFF po-
sition (disconnected).
Z When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
Z When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Z Never short-circuit the battery terminals with metal
objects.
Z Do not weld, grind or smoke near a battery.

SWARNING
Batteries produce explosive gases. Keep away any
flame, spark or cigarettes. Always provide good ven-
tilation when charging a battery or using a battery in
an enclosed space. Always protect your eyes when
working near a battery.

SWARNING
Before carrying out any welding on the machine or
repair work on the electrical circuit, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire mark-
ings.

SWARNING
Always store batteries in a safe place, out of the
reach of children.

SWARNING
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
 Copyright ©

118 SECTION 55 - ELECTRICAL SYSTEM

Z Remove the terminal covers and disconnect the

cables, first from the negative terminal (1) then the
positive terminal (2).
Z Remove the nuts and washers (3), the clamping
bar (4) and the brackets (5) and remove the old bat-
tery.
Z Install the new battery.
Z Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Z Clean the cables and the connecting terminals and
coat them with grease.
Z Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the termi-
nal covers.

SWARNING
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).

SECTION 55 - ELECTRICAL SYSTEM
6.4 MAINTENANCE
SPECIFIC GRAVITY
The specific gravity of the battery electrolyte indi-
cates the state of charge.
Fully charged the specific gravity of the electrolyte is
1.280 minimum at 25 °C (77 °F).
Alternatively the approximate state of charge can be
measured by using an accurate digital volt meter (+/
-0.01V) as follows:
Less than ................. 10.5 V Battery unserviceable*
Less than ....................... 11.8 V Battery discharged
Less than ......................12.3 V Battery 1/2 charged
Better than .................. 12.6 V Battery fully charged
* See note under tests for possible recovery of a
mildly sulphated battery.
Battery voltage to be taken with the battery unload-
ed and:
A. After the battery has rested unloaded for at least
4 hours.
B. If the vehicle has recently run or battery has re-
cently been charged, switch on headlamps for 2
minutes.
When a battery discharges, sulphuric acid in the
electrolyte combines chemically with the plates and
this action lowers the specific gravity of the solution.
A battery hydrometer will determine the specific
gravity of the electrolyte in a cell and the amount of
unused sulphuric acid in the solution is a measure of
the degree of charge of that cell.
The lower the temperature at which a battery is re-
quired to operate, the more necessary it is that the
battery is maintained in a fully charged condition.
For example a battery with a low specific gravity of
1.225 at 27 °C will operate the starting motor at
warm ambient temperatures but may not, due to
lower battery efficiency at a low temperature.
Table shows the effect of temperature on the effi-
ciency of a typical battery.
Temperature Efficiency of a fully
charged battery
temperature
25.0 °C 100%
-4.5 °C 82%
-24.0 °C 64%
-27.5 °C 58%
-31.0 °C 50%
-34.5 °C 40%
-37.5 °C 33%
Maximum battery life will be obtained if the correct
care and periodic inspection is given. It is important
that output capacity should not be exceeded by con-
stant and excessive overloading and that charging
requirements are maintained.
Copyright ©
119
SERVICING
SWARNING
Battery electrolyte causes severe burns. The bat-
tery contains sulphuric acid. Avoid any contact with
the skin, eyes or clothing.
Antidote:
EXTERNAL: rinse well with water, removing any
soiled clothing.
INTERNAL: avoid vomiting. Drink water to rinse
your mouth. Consult a doctor.
EYES: rinse abundantly with water for 15 minutes
and consult a doctor.
Battery terminal tightness check ... Every 250 hours
Electrolyte level inspection.......... Every 1000 hours
When servicing a battery the following steps should
be observed:
Z Maintain the electrolyte to the recommended level
of 6 mm above the plates. If this is not observed
the acid will reach a high concentration that will
damage the separators and impair the perform-
ance of the plates.
Z Use only distilled or de-mineralized water, do not
overfill and never use tap water or water from a
rain barrel or other source.
Z Always keep the battery at least 75% charged oth-
erwise the plates will become sulphated and loss
of efficiency will result with possible damage from
freezing at low temperatures.
Z Avoid overcharging the battery as excessive
charging will create high internal heat that will
cause plate grid deterioration and produce water
loss.
Z When fast charging ensure the battery tempera-
ture does not exceed 50 °C.
Z Do not add sulphuric acid to a cell unless the elec-
trolyte has been lost through spilling. Before re-
plenishing ensure the solution is at the correct
specific gravity. A slow charge is the only method
to be employed to fully charge a battery. A high
rate charger can be used to quickly boost the bat-
tery capacity but this must be followed by a slow
charge rate to bring the battery to full capacity.
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120 SECTION 55 - ELECTRICAL SYSTEM

DRY CHARGED RECHARGING DEEPLY DISCHARGED

Z Remove the battery cell vent plugs.
Z Fill each cell to the recommended level with elec-
trolyte of 1.260 specific gravity.
Dry charged batteries must be prepared for service
as follows:
NOTE: the electrolyte must be diluted sulphuric acid
preferably at a temperature of 21°-32 °C.
Z After filling, allow the battery to stand for 15 min-
utes then re-check the electrolyte level and top up
if necessary.
Z Charge the battery for 4 hours at a rate of 5-8 am-
peres and check that all cells are gassing freely.
Z Install the battery cell vent plugs.
CHARGING THE BATTERY
Before charging a battery:
Z Thoroughly clean the battery casing and cell cov-
ers with dilute ammonia or hot water and clean the
terminals.
Z Check the level of the electrolyte in each cell and,
if below plates, add distilled water to bring above
plate level.
The recommended method to recharge a mainte-
nance free Pb-Ca battery is to use a constant volt-
age charger. For deeply discharged batteries a 48
hours charging period at 16 voltsis recommended,
with current limitation, (47.5 A for 95 Ah).
This system is self regulating: high current is deliv-
ered at the beginning (when battery voltage is low),
lower and lower current is then absorbed when bat-
tery reaches full charge (and its voltage is high).
If only constant current chargers are available it is
recommended to use the current levels and times.
The figures are intended for deeply discharged bat-
teries. If the battery is only 50% discharged use one
half of the time listed (slow charge programs). For
other states of discharge reduce proportionally the
time of charge. Whenever possible use the slowest
charge program to increase the battery’s life.
If when charging the battery, violent gassing or
spewing of electrolyte occurs, or the battery case
feels hot (50 °C or greater), reduce or temporarily
halt charging to avoid damaging the battery.

NORMAL (TOP-UP) CHARGING

Z With a slow charger use a rate of 3 to 6 amperes
for the time necessary to bring the battery to full
charge. This may take 36 hours or more if the bat-
tery is heavily discharged. A severely sulphated
battery might not accept a charge. When the bat-
tery is fully charged the cells will gas freely and the
specific gravity will remain constant. Remove the
charger after three consecutive hydrometer read-
ings taken at hourly intervals indicate that the spe-
cific gravity has stopped rising.
Z When using a fast or high rate of charge carefully
follow the manufacturers instructions. High rate
charging raises the temperature of the electrolyte
and unless the charger is equipped with an auto-
matic time or temperature device, the electrolyte
temperature could exceed 50 °C, which may cause
violent battery gassing and damage to internal
components.
Z Re-check the level of electrolyte in each cell and
add distilled water as necessary.

SWARNING
When a battery is being charged an explosive gas is
produced. Do not smoke or use an exposed flame
when checking the electrolyte level and ensure the
charger is switched off before connecting or discon-
necting to avoid sparks which could ignite the gas.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 121

6.5 TESTS

Before commencing battery tests check the battery ing system to determine the cause of the low
for clogged vents, corrosion, raised vent plugs or a battery charge.
cracked case.
Test equipment required: NOTE: if distilled water has recently been added the
Z Hydrometer. battery should be recharged for a short period oth-
Z Battery starter tester (High rate discharge tester). erwise accurate hydrometer readings will not be ob-
Z Thermometer. tained.
Z Battery Charger.
If the battery has been charged under static condi-
SPECIFIC GRAVITY tions, denser electrolyte will accumulate at the bot-
This test will determine the state of battery charge. tom of the cells. The battery should be shaken
1. With the float in the vertical position take the periodically to mix the electrolyte, this will improve
reading. the charge rate and provide a more accurate hy-
2. Adjust the hydrometer reading for electrolyte drometer reading when tested.
temperature variations by subtracting 4 points
PERFORMANCE TEST
(0.004 specific gravity) for every 5.5 °C below
the temperature at which the hydrometer is cal- The performance test is to determine if the battery
ibrated and by adding 4 points (0.004 specific has adequate capacity to turn the engine. The volt-
gravity) for every 5.5 °C above this temperature. age reading obtained is used to determine the bat-
The following examples are calculated using a hy- tery condition. Prior to testing, ensure the electrolyte
drometer calibrated at 30 °C. level is correct and the open circuit voltage is 12.5 V
or more. The battery may be tested on or off the
Example 1: tractor.
Temperature below 30 °C 1. Set the current control switch of the battery
Electrolyte temperature...................................19 °C starter tester (high rate discharge tester) to the
Hydrometer reading ........................................1.270 “off” position and the voltage selector switch
Subtract (11.0 / 5.5) x 0.004 ...........................0.008 equal to, or slightly higher than, the rated battery
Corrected specific gravity................................1.262 voltage. Connect the tester positive leads to the
battery positive terminal and the negative leads
Example 2: to the negative battery terminal.
Temperature above 30 °C 2. Turn the current control knob until the ammeter
Electrolyte temperature...................................40 °C reading is half the CCA rating of the battery and
Hydrometer reading ........................................1.220 take the voltage reading.
Add (10.0 / 5.5) x 0.004 ..................................0.007 Z If the reading is 9.6 volts or more after 15 seconds,
Corrected specific gravity................................1.227 the battery has an acceptable output capacity and
3. Use the following table to determine the state of will readily accept a normal charge.
charge. Z If however the reading is below 9.6 volts, the bat-
tery is considered unsatisfactory for service and
State of Correcte Correcte Average should be test charged as described below.
Charge d specific d specific battery
gravity @ gravity @ voltage SCAUTION
15 °C 25 °C
Do not leave the high discharge load on the battery
100% 1.295 1.287 2.76 for periods longer than 15 seconds.
75% 1.253 1.246 12.52
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84

NOTE: specific gravity should not vary more than

0.025 points between cells.

4. If the specific gravity is 1.280 or more the battery

is fully charged and in good operating condition.
5. Should the corrected specific gravity be below
1.280, charge the battery and inspect the charg-

122 SECTION 55 - ELECTRICAL SYSTEM
TEST CHARGING
This test is designed only for batteries that have
failed the previous capacity test.
1. Attach the battery starter (high rate discharge
tester) positive leads to the battery positive ter-
minal and the negative leads to the battery neg-
ative terminal.
2. Connect the battery charger positive lead to the
battery positive terminal and the negative lead
to the battery negative terminal.
3. Turn the charger timer past a “3 minutes” charge
indication and then back to the “3 minutes”
mark.
4. Set the charging rate as close as possible to 40
amperes.
5. After 3 minutes at this fast charge take the volt-
meter reading.
Z If the total voltage is over 15.5 volts the battery is
unsatisfactory and is probably sulphated or worn
out and should be replaced.
NOTE: a mildly sulphated battery can be recovered
by using a multiple battery type charger, with an
open circuit upper voltage limit of 50 volts. Owing to
the high resistance of a sulphated battery, it will pri-
marily require a high voltage setting to overcome the
resistance of the sulphation initially there may be no
visible acceptance of the charge. After a few min-
utes of inactivity a small charge will be apparent, fol-
lowed by a rapid increase in the charge rate. The
charge rate must not exceed 14.0 amperes or the
electrolyte temperature 50°C. When the ampere
rate has stablished, reset the volts until the charge
rate is a steady 5 amperes. Continue at this rate un-
til the electrolyte specific gravity stops rising at ap-
proximately 1.275 - 1.280 at 20 °C (68 °F), this can
take up to 48 hours of charging. Stand the battery
for 24 hours and then conduct the capacity test de-
tailed previously.
Z If the total voltage is under 15.5 volts, test the spe-
cific gravity of each cell and re-charge the battery
to the following scale:
Specific Gravity Fast charge up to:
1.150 or less 60 minutes
1.151 to 1.175 45 minutes
1.176 to 1.200 30 minutes
1.201 to 1.225 15 minutes
(Slow charge only)
NOTE: when battery problems are experienced the
fan belt tension and the complete charging system
should be checked.
Copyright ©
COMMON CAUSES OF BATTERY FAILURES
Z Internal open circuit.
Z Internal short circuit.
Z Loss of electrolyte.
Z Separation of active materials from grids.
Z Accumulation of sulphate crystals too large to dis-
perse.
These failures are normally caused by the following:
Z Failure of inter cell components.
Z Excessive crystal growth may puncture the sepa-
rators and cause short circuits.
Z Excessive over charging (charging system mal-
function, boost/recovery techniques with high volt-
age, operation in very high temperatures).
Z Freezing of electrolyte. A fully charged battery
does not freeze until -65 °C. A 50% charged bat-
tery freezes between -17 °C and -27 °C. Fully dis-
charged electrolyte freezes at -3 °C to -11°C.
Excessively high boost charging and gassing will
also cause separation of active materials from the
grids. Separation destroys the chemical function of
the battery.
Z Crystal growth occurs whenever batteries are left
discharged. High temperatures and extended dis-
charged periods increase this condition.
At room temperature after one week the battery is
unlikely to recover on the vehicle.
Recharge will require a higher constant voltage.
After 3 weeks the battery will have suffered perma-
nent degradation and the procedure detailed previ-
ously for charging a “Deeply Discharged” battery
should be followed.
When fully charged, batteries have a long shelf life.
The lead calcium type battery self discharges at 3%
per month. This means that it will take 16 months to
lower to 50% charged. On the tractor the quiescent
load is about 50 mA. To predict rundown on a static
vehicle this should be added as approximately 8 Ah
per week.
It is worth stressing that when cranking, if a battery
starts to fade, it is beneficial to stop and allow two
minutes for the battery to recover. The recovery time
should be increased as the temperature decreases.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 123

6.6 CONNECTING A BOOSTER BATTERY

SWARNING
When the electrolyte of a battery is frozen, it can ex-
plode if you attempt to charge the battery or if you try to
start the engine using a booster battery. Always keep
the battery charged to prevent the electrolyte freezing.

SWARNING
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.

IMPORTANT: make sure that the voltage of the

booster batteries is the same as that of the machine
circuit (12 V).

Z Open the battery box and then remove the tool box.
Z Remove the terminal covers.
Z Connect the positive (+) jumper cable to the posi-
tive (+) terminal of the machine's battery.
Z Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Z Start the engine.
Z First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Z Install the terminal covers.
Z Install the tool box and close the battery box.

6.7 BATTERY MASTER SWITCH

The battery master switch is located under the con-

sole behind the brake pedals and is used to discon-
nect the electrical system completely from the
battery.
When the master switch is in vertical position, the
circuit is disconnected.
When the master switch is in horizontal position, the
circuit is connected.

SWARNING
The battery master switch must be switched off at
the end of each working day, for machine service or
for any operations on the electrical system. It acts as
an anti-theft device when the cab doors and win-
dows are locked.
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124 SECTION 55 - ELECTRICAL SYSTEM

7. COMPONENT TESTING
7.1 GENERAL INTRODUCTION

No special tools are required to remove or replace

electrical components.
Refer to the appropriate section of this Service Man-
ual for overhaul procedures to cover the starter mo-
tor and alternator.
Fault finding of electrical systems should be carried
out in a logical and methodical fashion. A few min-
utes spent understanding the system and analysing
the symptoms can save considerable time.
An essential piece of equipment for checking electri-
cal systems is a good quality multimeter with a high
impedance which can measure voltage, current and
resistance. F28375

NOTE: labelling of connectors prior to disassembly

will greatly assist when reconnecting any harness.

Where it is necessary to clean the multiple connec-

tors, a contact spray should be used.

IMPORTANT: DO NOT use a cleaner that contains

trichloroethylene which will dissolve the plastic con-
nectors.

The wiring harnesses contain wires which are colour

coded for identification.
Each harness can be removed and replaced, but
certain precautions must be observed:
Z Disconnect or isolate the battery, negative terminal
first, prior to disconnection or removal of any wiring
harness.
Z Prior to removal, note the harness routing, clamp-
ing positions and terminal connections.
Z On replacement, be sure that the harness routing
is not in contact with sharp edges, the exhaust sys-
tem or moving parts.
Z Check connections for wire colour matching.
Z Use a light coating of di-electrical grease on the
connector pins to prevent corrosion.
Z Be sure that all connectors are fully engaged and
no conductor is exposed.
Z Tape back unused connectors.
Z Be sure that ground connections are clean with
metal-to-metal contact. Use toothed lock washers
for good ground connections.
Z Be sure that fuses are of the specified rating.
Z Check the circuit current draw before connecting
power to the harness.
Z Check polarity of the battery before connecting
power to the harness.
Z When it is necessary to remove or partially discon-
nect a wiring harness, label each connector before
removal from its mating instrument.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 125

7.2 COMPONENT TESTING

In general with the key start on there should be 12 V

found at the component connections.
Where 12 V is not present check fuses, relays and
wiring for breaks.

7.3 GROUND POINTS

NOTE: always ensure the ground points are clean

and functional. A poor ground will cause the electrics
to fail.
A

Ground point A - Starter motor (Engine harness)

Ground point A is also linked to ground point B.

F28376

Ground point B - Right hand console (front con-

sole harness)
This is also linked to ground points A, C, and D.

F28377

Ground point C - Rear of chassis (Chassis har-

ness)
This is also linked to ground point E.

F28378
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126 SECTION 55 - ELECTRICAL SYSTEM

Ground point D - Fuse board

This is also a back-up ground point for Location E. XC5 K5
F5/B
K6
F5/A
F6/C F7/C F8/C K7

F6/B F7/B F8/B K8

F6/A F7/A F8/A K9

15v 30v GND D

F28379

Ground point E - Right hand console (Cab main

harness)
This is also a link to ground point B and C.

F28405

Ground point F - Top right hand B pillar (roof har-

ness) F

F28380

Ground point G - Operator’seat light

F28381
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SECTION 55 - ELECTRICAL SYSTEM 127

KEY-START AND STOP SWITCH -S17

NOTE: when the key-start/stop switch is turned to

the “ON” position the audible alarm will be activated
until the engine is started or the key returned to the
off position.

Key start
1. Not used
2. Off
3. Ignition “ON”
4. Engine start

SWITCH -X71
X71
Test procedure
Voltage: 5: CM:A:2.5
6: CM:A:2.5
CM:A:2.5
Pin Key switch position 7: CM:B-N:1.5
No. OFF Pos. I Pos. II Pos. III 9: CM:M-N:1.5
CM:M/N:1
9 0V 0V 12 V 12 V
7 0V 0V 0V 12 V 4: CM:M-N:1.5
CM:M-N:1.5
4 0V 0V 12 V 12 V 1: CM:R:1.5
CM:R:1.5
5-6 0V 12 V 12 V 12 V 2: CM:R:6 F28383

2 12 V 12 V 12 V 12 V

Continuity:

Pin Key switch position

No. OFF Pos. I Pos. II Pos. III
9 X X
7 X
4 X X
5-6 X X X
2 X X X
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128 SECTION 55 - ELECTRICAL SYSTEM

STARTER MOTOR -M1

Test procedure

Key switch position

OFF AUX. ON START
0V 0V 0V 0V
Resistance 0.3 Ohms

F28384

STARTER RELAY -KO1

Test procedure

Pin Key switch position

No. OFF AUX. ON START
1 0V 0V 0V 12 V
2 0V 0V 0V 0V
3 12 V 12 V 12 V 12 V
4 0V 0V 0V 12 V
F28385

FUSES - 80 A -FG1
The main fuses have been designed to protect the
whole electrical system. Fuses fitted are dependent
on models.

Test procedure
Battery voltage should be found both sides of fuse at
all times.

F29547
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 129

SAFETY START RELAY - K3

Powershuttle lever in forward or reverse (engine
will not start) park brake ON, klaxon sounds.

Powershift lever in forward upshift or reverse up-

shift. (engine will start) park brake ON, klaxon
sounds.

Pin Key switch position

No. OFF Pos. I Pos. II Pos. III
K12
9 0V 0V 12 V 12 V K10 K11
7 0V 0V 0V 12 V K1
+BZ1
4 0V 0V 12 V 12 V CN/1 CN/2 K2
5-6 0V 12 V 12 V 12 V
2 12 V 12 V 12 V 12 V F1/C F2/C

F1/B F2/B CN/6

Pin Key switch position
No. F1/A F2/A
OFF Pos. I Pos. II Pos. III CN/3
9 X X F3/C F4/C
K3
7 X F3/B F4/B
K4
4 X X F30383

5-6 X X X
2 X X X
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130 SECTION 55 - ELECTRICAL SYSTEM

ALTERNATOR -G2
This sends a square wave signal, the frequency of
which varies between 142.52 855 Hz (480 - 3060
rpm) to the instrument panel.
With the engine running, the warning light should go
out. If not, disconnect the wire connected to the ter-
minal D+ (pink wire).
When D+ is not connected and the warning light
goes out, there is a fault with the alternator. If it does
not go out, then check the bulb and the wiring loom.

F28388

S-N:1

F28389

TRANSMISSIONS
POWERSHUTTLE DISCONNECT -X23 / X28
Energizes the transmission dump solenoid at 12 V.

F28392

Test procedure
Continuity should be found between pin 1 and pin 2 X23
when switch is operated.

2: RM:A-R:1
1: RM:B-R:1

X28

1: RM:A-R:1
4: RM:C-N:1
1: RM:B-R:1
3: RM:N:1
F28391
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 131

POWERSHIFT EGS CONNECTOR

The EGS receives input from the FWD Switch,
brakes, switches, transmission disconnect switch,
temperature sensor and speed sensor. The EGS
also sends signals to the transmission control valve.
For input and output tests to check correct operation
of the EGS, refer to Section 21.

Test procedure
Test procedure of the speed sensor refer to the next
page.

POWERSHIFT CONTROL VALVE

The control valve receives signals switching ON or
OFF the solenoids allowing the desired gears to be
selected. A variable current solenoid receives a re-
ducing signal from the EGS controlling modulator.
The control valve is fitted with a combined tempera-
ture and speed sensor which sends signals back to
the EGS.

Test procedure
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
F28394

DESCRIPTION
Pin
H M
No.
A 27.5 Ω -
B 27.5 Ω -
C 27.5 Ω -
D 27.5 Ω -
E 27.5 Ω -
F 27.5 Ω - F28395

G - 14 Ω
K - 31 Ω

*A Speed sensor plus output 24

B Forward Lo/Hi solenoid
C Forward/neutral solenoid
D Range 1/2 solenoid
E FWD solenoid
F Reverse neutral solenoid
G Direction modulation solenoid
K Range modulation solenoid
L Transmission temperature out ground
M Control valve common plus
 Copyright ©

132 SECTION 55 - ELECTRICAL SYSTEM

POWERSHIFT SPEED SENSOR TEST

Disconnect from control valve and fit the 12 pin con-
nector from special tool.
Connect the power socket into the 12 V power sock-
et. Install the probes from a multimeter into the tool.
Raise the unit off the ground and observe voltage
(V1). Turn the rear wheel which in turn rotates the
transmission output shaft, observe the second volt-
age (V2).

F28394

Test procedure

Pin
V1 V2
No.
A 0.6 - 0.8 1.3 - 1.5
The special tool connects to pin A speed sensor plus
output, and pin J speed sensor/temperature sensor
ground.

F28397

Description
A Speed sensor +
B FWD request
C Disconnect request input A
B M
D Speedometer output
C N L
E Diagnostic link input P U
F Analogue Input 1 D V K
G Analogue Input 0 R T
H - E S J
J - F H
G
K PWM solenoid supply
L Solenoid 3
M PWM 1 F28398

N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
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SECTION 55 - ELECTRICAL SYSTEM 133

POWERSHIFT EGS OVERRIDE -S48

In situations where a “MANUAL” gear change (up or
downshift) is required the powershift auto change
can be overridden by selection of this console
mounted switch.

Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.

7: Z/N1

5: N1

F28400

OIL PRESSURE SWITCH - POWERSHIFT

Energized at 12 V if the transmission pressure is to
low, the warning lamp will flash.

F28402

Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.

Pin
Sender Resistance Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1

F28403
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134 SECTION 55 - ELECTRICAL SYSTEM

OIL PRESSURE SWITCH - POWERSHUTTLE

If the transmission pressure is to low, the warning
lamp to flash.

F28404

Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.

Pin
Sender Resistance Z-B:1
No.
1 12 V at low pressure 0.3 Ω N:1

F28403

PARKING BRAKE SWITCH

When the handbrake has been applied, the switch
will be closed and the warning lamp is illuminated.
An alarm / klaxon will sound if the handbrake is on
with the transmission shuttle lever applied.

Test procedure
Brake engaged:
switch closed warning light illuminated.
S18

Brake disengaged:
switch open warning light off. 1: FM:G-R:1

1: FM:N:1

F28407
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SECTION 55 - ELECTRICAL SYSTEM 135

CAB
FRONT INSTRUMENT PANEL -X70 12 PIN
The front instrument panel is sent signals from the
brake oil level sender, transmission speed sensor,
light switch and indicator switch.
At the rear of the panels are connectors that are at-
tached to the vehicle harness system.
These connectors and functions are listed on the fol-
lowing pages.

SIDE INSTRUMENT PANEL -X22 20 PIN

Receives signal from sensors to display, hours, en-
gine RPM, oil pressure, fuel level and signals to
warning and indicator lights.

FRONT PANEL CONNECTOR - CONNECTOR -

AMPERE 070 12 VIE -X70 POWERSHUTTLE
5 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. 12 V key start
2. Ground:
check continuity
3. Tachometer:
Signal from W output of the alternator
4. Dipped beam: 12 6
green warning light illuminates at 12 V with multi F28412
function light switch on
5. High beam -blue warning light illuminates at 12
V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. Not used
9. Not used
10. Not used
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on
12. Brake oil level:
red warning light when the input is connected to
ground with Ignition on 12 V
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136 SECTION 55 - ELECTRICAL SYSTEM

SIDE PANEL CONNECTOR - CONNECTOR

AMPERE 070 20 VIE -X22 POWERSHUTTLE
9 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. Air filter:
the red warning light is illuminated if the input is
connected to ground with ignition on 12 V
2. Engine oil pressure:
the red warning light is illuminated if the input is
connected to ground with ignition on 12 V 20 10
3. Battery: F28413
low battery charging the red warning light comes
on when the input is connected to + V DC. Igni-
tion on 0 V or engine running 12 V
4. Engine coolant temperature gauge:
the red warning light is illuminated if the input is
41 connected to ground with ignition on 12 V (At
75 °C indicator is on red the warning buzzer
sounds at 107 °C)
5. Fuel level gauge:
when the input is connected to ground with Igni-
tion on 12 V
6. Tachometer gauge:
signal from W output of the alternator
7. 12 V and backlighting
8. Ground - Check continuity
9. 12 V key start
10. Not used
11. Not used
12. Not used
13. Park brake - Red warning light hand brake on 0
V, hand brake off 12 V
14. 24 V option
15. Buzzer
16. Options
17. Options
18. Transmission low oil pressure - Red warning
light is illuminated and buzzer sounds if the input
is connected to ground. Ignition on 0 V, engine
running 12 V
19. Transmission oil temperature - Red warning light
illuminates if the input is connected to ground.
Ignition on 12 V
20. Engine cold start the yellow warning light comes
on when the input is connected to 12 V. Ignition
on 0 V preheat engaged 12 V
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SECTION 55 - ELECTRICAL SYSTEM 137

FRONT PANEL CONNECTOR - CONNECTOR -

AMPERE 070 12 VIE -X70 POWERSHIFT
5 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. 12 volt key start
2. Ground:
check continuity
3. Tachometer:
signal from W output of the alternator
4. Dipped beam: 12 6
green warning light illuminates at 12 V with multi F28412
function light switch on
5. High beam - Blue warning light illuminates at 12
V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. 4 wheel steer - Green warning light four wheel
input. With Ignition ON and 4WS selected 0.5 V
should be indicated. With 2WS or crab steer se-
lected 0 V should be indicated
9. Crab steer - Green warning light
10. 2 wheel steer - Green warning light two wheel
steer input. With Ignition ON and 2WS selected
1.5 V should be indicated. With 4WS or crab
steer selected 12 V should be indicated
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on
12. Brake oil level:
red warning light when the input is connected to
ground with ignition on 12 V
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138 SECTION 55 - ELECTRICAL SYSTEM

SIDE PANEL CONNECTOR - CONNECTOR

AMPERE 070 20 VIE -X22 POWERSHIFT
9 1
Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. Air filter:
the red warning light is illuminated if the input is
connected to ground with Ignition on 12 V
2. Engine oil pressure:
the red warning light is illuminated if the input is
connected to ground with Ignition on 12 V 20 10
3. Battery: F28413
low battery charging the red warning light comes
on when the input is connected to + V DC. Igni-
tion on 0 V or engine running 12 V
4. Engine coolant temperature gauge:
the red warning light is illuminated if the input is
41 connected to ground with Ignition on 12 V (At
75 °C indicator is on red the warning buzzer
sounds at 107 °C)
5. Fuel level gauge:
when the input is connected to ground with igni-
tion on 12 V
6. Tachometer gauge:
signal from W output of the alternator
7. 12 V and backlighting
8. Ground - Check continuity
9. 12 V key start
10. Not used
11. Not used
12. 30 volt battery
13. Park brake - Red warning light hand brake on 0
V, hand brake off 12 V
14. 24 V option
15. Buzzer
16. Options
17. Options
18. Transmission low oil pressure - Red warning
light is illuminated and buzzer sounds if the input
is connected to ground. Ignition on 0 V, engine
running 12 V
19. Transmission oil temperature - Red warning light
illuminates if the input is connected to ground.
Ignition on 12 V
20. Engine cold start the yellow warning light comes
on when the input is connected to 12 V. Ignition
on 0 V preheat engaged 12 V
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SECTION 55 - ELECTRICAL SYSTEM 139

4WD SWITCH S2

Test procedure

Continuity
Switch OFF Position 1 Position 2
Pin 7 to pin 5 Pin 5 to pin 3 Pin 1 to pin 3
Pin 6 to pin 8 Pin 4 to pin 6 Pin 2 to pin 4

Voltage:
Ignition ON: Pin 3 = 12 V
Pin 6 = 9 V
F28417

BRAKE PEDAL SWITCHES -S32 / S33

Test procedure

Continuity:
Brakes not applied: no continuity.
Brakes applied: continuity, between the two centre
pins of each switch.
Both brake pedals must be applied to allow 12 V to
relay.

F28419

Voltage:
Left switch:
White / red wire 12 V continuous with ignition ON
Red wire 12 V pedal depressed
0 V pedal released
Right switch:
Red wire 12 V pedal depressed
1: R:1 1: R:1
0 V pedal released
Red - Black wire 12 V pedal depressed 2: R-N:1 2: B/R:1
0 V pedal released

F28420
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140 SECTION 55 - ELECTRICAL SYSTEM

BRAKE OIL LEVEL SWITCH -S31

When the switch is activated due to low oil level this
sends a signal to the instrument cluster to illuminate
the low brake fluid level warning lamp.

Test procedure:
Continuity:
With the fluid level correct there should be no conti-
nuity through the switch. Continuity should be seen
when the level is low or the test button pushed.
Voltage:
With the Ignition ON there should be 12 V at the 1: G-R:1
Red/Black terminal.
2: R/N:1

F28422

FRONT WORK LAMP SWITCH S11 (1) - REAR

WORK LAMP SWITCH S12 (2) MAIN LIGHT
SWITCH
12 V should be found at the switch only after main
light switch is on and key start activated.

Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 3
and 2 and 8.

F28417
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SECTION 55 - ELECTRICAL SYSTEM 141

HAZARD SWITCH -S10

12 V should be found at this switch at all times re-
gardless of key start position.

Test procedure

Pin No. Switch OFF Switch ON

1 to pin 4 -
3 - to pins 5/6/7
4 to pin 1 - 1: S-N 3: A-G
5 - to pins 2/3/6/7 7: A/V 4: H-R

6 - to pins 2/3/5/7 6: L/B 5: L/R

7 - to pins 2/3/5
F28428

FLASHER MODULE K12

Operational at all times in conjunction with the haz-
ard switch.

K10 K12
K11

+BZ1
XC1 XC2 K2

F1/C F2/C
F28430

Continuity

Pin Hazard / Indicator

No. Switch OFF Switch ON
CL 12 V 12 V
+ - 12 V - 0 V - 12 V - 0 V
31 - 12 V - 0 V - 12 V - 0 V
PR - -

F28431
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142 SECTION 55 - ELECTRICAL SYSTEM

MULTI FUNCTION SWITCH -S41

Switch Continuity
All Indicator Beam Wiper
Wind-
Pin switc
screen
No. hes Left Right Low High On
washer
OFF
1
2 pin 7
3 pin 4
4 pin 5 pin 3
5 pin 4
6 pin 8
7 pin 2 pin 8
8 pin 6 pin 7
9 pin 11
10 pin 11
11 pin 9 pin 10
12 2: L-B:1
4: G/R:1
12
5: V/N:1.5
6: A/B:1
7: A/N:1
8: A/R:1 1 7
9: L:1
10: A-V:1 6
11: L-N:1

F28433

FRONT WIPER MOTOR M5 (1) - REAR WIPER

MOTOR M4 (2)
1
Energized at key start at 12 V.

F28436

Test procedure

Pin No. Continuity Continuity

1 pin 3 pin 5 2 Ω
3 pin 5 2 Ω -
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SECTION 55 - ELECTRICAL SYSTEM 143

4WS -STEERING SELECTOR SWITCH -S47

At key start 12 V should be found at the switch and
is directed to the steering sensors when a switch se-
lection is made.

Test procedure
With ignition ON

Pin 2WS 4WS CRAB

A 12 V 12 V 12 V
B - - 12 V
C
C - 12 V - V/N

B L-R

C-G
A
F28438
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144 SECTION 55 - ELECTRICAL SYSTEM

STEERING CONTROL UNIT

The steering control unit controls the different steer-
ing functions that can be selected from the switch
S47.
When changing steering mode, the light for the cur-
rent mode is extinguished and the light for the new
mode starts to flash. When movement of the steer-
ing wheel is detected, the light for the new mode re-
mains steady.

Connector pin out description

12 pin connector -X95:
X95
1: CM:Z/B:1.5
Pin Function Signal 2: CM:C:1
3: CM:H-L:1.5
1 Crab steering warning light - 4: CM:A-R:1
5: CM:V-B:1 12
2 Buzzer configuration -
6: CM:V/N:1
3 Front alignment sensor input +12 7: CM:R-G:1
8: CM:N:1 7
4 Crab steering control +12 9: CM:A-B:1 1
10: CM:L/N:1
5 Buzzer output - 11: CM:M:1 6
12: CM:V/B:1
6 Rod iron steering control +12 F28441

7 Control unit supply +12

8 Ground -
9 Speed sensor input -
10 Rear alignment sensor input +12
11 2WS warning light -
12 4WS warning light -

8 pin connector -X96:

Pin Function Signal X96

1 EV2A output +12 1: CM:L/R:1

2: CM:S/N:1
2 EV2B output +12 3: CM:H/N:1
4: CM:L-N:1 8
3 EV3A output +12
5: CM:A/V:1
4 Ground - 6: CM:R/N:1
7: 5
1
5 Front sensor supply output +12 8: CM:M/B:1
4
6 Rear sensor supply output +12
7 Available optional output +12 F28442

8 EV3B output +12

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SECTION 55 - ELECTRICAL SYSTEM 145

Solenoid valve operation Speed pulses

Crab/4WS > 2WS
When the rear axle sensor detects alignment of its
axis, the control unit de-energizes the active steer-
ing solenoid valves and activates the solenoid
valves for 2WS.
2WS > Crab/4WS
When the rear axle sensor detects bridge align-
ment, all the solenoid valves for 2WS are de-activat-
ed and the solenoid valves for the selected mode
are energized.
Crab > 4WS and 4WS > Crab
When the rear axle sensor detects alignment the
2WS temporarily activates (energizing the corre-
sponding solenoid valves) until, after overcoming
the condition of rear bridge alignment, the desired
steering type activates when, by reversing the steer-
ing swing direction, the rear axle sensor detects
alignment.
Solenoid valve failure
The operation condition of any solenoid valve output
is tested each time the selected steering requires its
supply. Even when only one solenoid valve output is
short circuited or open, the control unit provides to
cut the supply to all the solenoid valves by means of
the self protection (the control unit is locked) and to
signal this condition (short - or open - circuit) by
means of the three warning lights relative to steering
flashing at the same time. Once the solenoid valve
causing the failure has been de-energized or the
correct operation has been reset.
Speed pulses are drawn from EGS-CLARK control
unit. Output reference values of clark transmission
are;
Z 7 Hz for 1 km Æ
Z 14 Hz for 2 km Æ
Z 35 Hz for 5 km Æ
values in volts -8 and +8.
The speed calculation has been determined with a
tyre having a circumference of 4.165 m.
Steering type storage
The steering type is stored in a non-volatile memory
each time the machine is turned off. This information
is therefore stored for an indefinite time even with
the supply cut off.
Start-up and axle recovery
The control units are supplied with a storage of the
last steering selected at two wheels. With this steer-
ing type selected, it is always possible to recover the
axle alignment; “short-circuit” the sensor or front and
rear axles, supply the machine (with the switch in 2
wheel position) and select the type of 4 wheel steer-
ing enabling the bridge alignment.

Buzzer operation
Buzzer operation depends on setting of pin 2 of the
12 way connector:
Z Pin 2 not connected (North America only) If 12 km/
h is exceeded in crab mode, the buzzer sounds.
Z Pin 2 grounded (Outside of N/America). If 12 km/h
is exceeded in crab or 4WS mode, the buzzer
sounds.
Buzzer operation is intermittent, 250 ms on and 250
ms off.
The control unit is set at 9 km/h; steering mode
change is not possible when this speed is exceed-
ed.

Solenoid valve output

Solenoid 2WS 4WS CRAB

EVA2 X
EVA3 X X
EVB2 X X
EVB3 X
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146 SECTION 55 - ELECTRICAL SYSTEM

4WS REAR AXLE STEERING SENSOR -S42

At key start 12 V should be found at the switch and
is directed to the steering sensor when the switch
selection is made.

F28443

TEST PROCEDURE -X98

Pin 2WS 4WS CRAB X98

A 12 V 12 V 12 V
B - - -
C - - - A: RM:L/N:1
B: RM:N:1
C: RM:R/N:1

F28444

4WS FRONT AXLE STEERING SENSOR -S40

At key start 12 V should be found at the switch and
is directed to the steering sensor when a switch se-
lection is made.

F28445

TEST PROCEDURE -X97

Pin 2WS 4WS CRAB X97

A 12 V 12 V 12 V
B - - -
C - - - A: RM:H-L:1
B: RM:N:1
C: RM:A/V:1

F28446
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SECTION 55 - ELECTRICAL SYSTEM 147

STEERING SOLENOIDS
Energized at 12 V but governed by the steering proc-
essor.

F28447

Solenoid connections, viewed from the top. Arrow

denotes front of tractor.
EVA2 - X91 EVB2 - X92
Solenoid 2WS 4WS CRAB
EVA2 0V 0V 12 V
EVA3 0V 12 V 12 V
EVB2 12 V 12 V 0V
EVB3 12 V 0V 0V

EVA3 - X93 EVB3 - X94

F28448

TEST PROCEDURE
X91
Pin No. Solenoid Resistance
X92
1 0V 5.0 Ω
1: RM:L/R:1
2: RM:N:1

1: RM:S/N:1
2: RM:N:1

F28449

TEST PROCEDURE
X93
Pin No. Solenoid Resistance
X94
1 0V 5.0 Ω
1: RM:H/N:1
2: RM:N:1

1: RM:M/B:1
2: RM:N:1

F28450
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148 SECTION 55 - ELECTRICAL SYSTEM

DIFFERENTIAL LOCK SWITCH -S47

At key start the spring loaded switch has 12 V and
when operated energizes the differential solenoid
valve.

Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
1: M/B1

5: C-B1

F28452

TEST PROCEDURE -EV7

X8
Pin No. Solenoid Resistance
1 0V 5.0 Ω

1: RM:CL:1
2: RM:N:1

F28453
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SECTION 55 - ELECTRICAL SYSTEM 149

LOADER
GLIDE RIDE CONTROL -S5
Designed to reduce loader bounce when travelling
with an unladen bucket.

SWARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
If the switch is ON, upon engine start up the vehicle
will fall to the ground without any control.

Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 5.
1: C/N1

5: A-N1

F28456

TEST PROCEDURE -EV11

X34
Pin No. Solenoid Resistance
1 0V 5.0 Ω

1: RM:A-N:1
2: RM:N:1

F28457
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150 SECTION 55 - ELECTRICAL SYSTEM

LOADER LOCK VALVE (1)

The loader lock when actuated is designed to pre-
vent movement of the front loader during road travel.

Continuity should be found between pin 1 and 3.

F28417

Test procedure

Pin No. Solenoid Resistance

1 0V 5.0 Ω

1: RM:N:1
2: RM:C-L:1

F28461

DOUBLE DELIVERY CONNECTION (1) -S4

Auxiliary hydraulic line for external tool operation.
 Copyright ©

SECTION 55 - ELECTRICAL SYSTEM 151

Test procedure
(Switch off)
Continuity should not be found between any pins.
(Switch on)
Continuity shoud be found between pins 1 and 5.
1: C/N1

5: L-G1

F28464

TEST PROCEDURE -EV1

Pin No. Solenoid Resistance

1 0V 5.0 Ω

1: RM:N:1
2: RM:C-L:1

F28461

BACKHOE
SIDESHIFT LOCK SWITCH (1) -S7
At key start switch should have 12 V to release/en-
gage sideshift clamps.

Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity should be found between pins 1 and 5.
1: C/B1

5: B-N1

F28468
 Copyright ©

152 SECTION 55 - ELECTRICAL SYSTEM

SIDESHIFT LOCK SOLENOID LINK TEST

PROCEDURE -EV4

Pin No. Solenoid Resistance

1 12 V 9.7 Ω 1: RM:A-N:1
2: RM:N:1

1: RM:N:1
2: RM:C-L:1

F28469

BOOM LOCK SWITCH (1) -S8

At key start switch should have 12 V for operation of
the boom lock.

Test procedure
(Switch Off) - X25
Continuity should be found between pins 1 and 5.
(Switch On)
Continuity should be found between pins 5 and 7.
1: C-B1
7: L/G1

5: C/B1

F28472

BOOM LOCK SOLENOID -EV5

Pin No. Solenoid Resistance

1 12 V 7.5 Ω

1: R-V:1
2: N:1

F28473
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SECTION 55 - ELECTRICAL SYSTEM 153

BACKHOE HAMMER SWITCH -S30

At key start the foot switch should have 12 V for op-
eration of an attachment.

F28475

When switch is operated 12 V should be found at pin

2.

2: R-V
1: R-V:1

F28476

BACKHOE HAMMER SOLENOID -EV3

Pin No. Solenoid Resistance

1 12 V 7.5 Ω

1: R-V:1
2: N:1

F28473
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154 SECTION 55 - ELECTRICAL SYSTEM

HAND HAMMER SWITCH (1) -S3

At key start 12 V should be found at the switch for
operation of a hammer.

When the switch is operated 12 V should be found

at pin 1.

1: C-B1

5: C/B1

F28479

HAND HAMMER SOLENOID VALVE -EV2

Pin No. Solenoid Resistance

1 12 V 7.5 Ω

1: H-N
2: N:1

F28480
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SECTION 55 - ELECTRICAL SYSTEM 155

QUICK HITCH -BUCKET/TOOLS (1) -S6

An accessory for attachment of buckets and tools
activated at 12 V.

When switch is operated 12 V should be found at pin

5.

1: C/N1

5: V1

F28483

QUICK HITCH SOLENOID -EV12

Positioned on the backhoe chassis.

F28485

When switch is operated 12 V should be found at pin

1.
Solenoid resistance should be 9.7

2: V:1
1: N:1

F28486
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156 SECTION 55 - ELECTRICAL SYSTEM

REVERSING BUZZER HA1

Activated by 12 V at key start when reverse gear is
selected.

F28487

With reverse selected 12 V should be found at pin

connector.
Resistance of the buzzer 162 Ω.

M/B
N

F28488

FUEL LEVEL SENDER R3

The signal from the fuel sender potentiometer deter-
mining the fuel level displayed on the instrument
cluster gauge.

F28489

Test procedure
Approximate resistance:

Gauge indication Sensor resistance

Full 9Ω
Half 129 Ω
Empty 333 Ω
2: N
1: Z:1

F28490
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 82 - LOADER

1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3

2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 9
5. LOADER ARM REMOVAL.......................................................................................................................... 11
 Copyright ©

2 SECTION 82 - LOADER
 Copyright ©

SECTION 82 - LOADER 3

1. LOADER ATTACHMENT CONTROLS

WITH STANDARD LOADER BUCKET
Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls. The speed of movement of each control de-
pends on the tilting angle of the lever. In the interme-
diate position, two movements can be obtained
simultaneously.

WITH 4 IN 1 LOADER BUCKET

The function of the lever is identical to that of the ma-
chine fitted with the standard loader bucket, with the
addition of the clam control.

LOADER CONTROLS, NEUTRAL AND HOLD

When in the neutral/hold position (0) the attachment
movement can be stopped. As soon as the lever is
released, it automatically returns to the neutral posi-
tion (0) and the attachment remains in the position
where was when movement stopped.

RAISING THE LOADER ATTACHMENT

With the lever in position (1), the attachment rises.

LOWERING THE LOADER ATTACHMENT

With the lever in position (2), the attachment lowers.
 Copyright ©

4 SECTION 82 - LOADER

LOADER BUCKET FLOAT CONTROL

With the lever in position (3), the bucket follows the
contours of the ground without it being necessary to
operate the lever.

NOTE: in this position the lever does not automati-

cally return to neutral when it is released. It is neces-
sary to move it manually.

FILLING THE LOADER BUCKET

With the lever in position (4), the bucket rolls back
(fills).

DUMPING THE LOADER BUCKET

With the lever in position (5), the bucket rolls forward
(dumps).

LOADER ATTACHMENT AUTOMATIC RETURN

TO DIG
With the lever in position (6), the attachment lowers
and simultaneously the loader bucket places itself in
the digging position.

NOTE: it is possible to adjust the tilt angle for bucket

dig.
 Copyright ©

SECTION 82 - LOADER 5

4 IN 1 LOADER BUCKET CLAM CONTROL (if

fitted)
This control operates the opening and closing of the
4 in 1 loader bucket clam. To use the control it is nec-
essary to unlock the lever by means of the latch (A).
This control has three positions:
Position (0): Neutral/hold. As soon as the lever is re-
leased, it automatically returns to the neutral position
(0) and the clam remains in the position where it was
when movement stopped.
Position (1): Open clam.
Press the latch (A) and tilt the lever to the right.
Position (2): Close clam.
Press the latch (A) and tilt the lever to the left.

IMPORTANT: the latch (A) must be in the locked po-

sition when the clam is not being used. It does not
lock automatically, it has to be engaged manually.
 Copyright ©

6 SECTION 82 - LOADER

2. LOADER BUCKET SELF LEVELING

The self leveling linkage mounted on the right hand
loader arm and chassis automatically controls the
angle of the loader bucket during the raising cycle of
the lift arms to maintain a constant bucket level.
There is no self leveling during lowering.
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electrical circuit is completed and the so-
lenoid on the bucket spool is energized.
When the loader bucket control lever (3) is moved di-
agonally left to the return to dig position (2) the elec-
tromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging posi-
tion at which time the indicator on the rod of the buck-
et self levelling linkage will pass in front of the sensor
which de-energises the electromagnet on the bucket
spool enabling the spool to return to the neutral posi-
tion.

RETURN TO DIG SENSOR ADJUSTMENT

The return to dig system consists of an electromag-
net mounted on the loader bucket control valve
spool, a sensor (1) mounted on top of the loader arm
and a pointer attached to the tube of the bucket self
levelling linkage.
Z Place the bucket on the ground in the preferred dig-
ging position.
Z Check the dimensions of 88.5 mm and 7.5 mm are
maintained as shown.
Z Ensure the face of the sensor (1) is 6 mm from rod
(2).
As a visual aid for the operator, while seated in the
cab, the pointer mounted on the loader arm can be
seen to align with the pointer on return to dig linkage,
when the loader arms are lowered and the bucket is
in the level digging position.
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SECTION 82 - LOADER 7

3. LOADER ATTACHMENT SAFETY STRUT

Located on the left-hand side of the loader attach-
ment, this safety strut enables the loader attachment
to be locked in the raised position in case of defects
in the system.

LOCKED POSITION
Raise the loader attachment completely, stop the en-
gine and remove the ignition switch key.
Remove the pins and the safety strut from the loader
arm. Put the pins back in place.

Place the strut on the cylinder rod and install the re-
taining strap.

UNLOCKED POSITION
Remove the strut from the cylinder rod.
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8 SECTION 82 - LOADER

Install the safety strut with the pins on the loader arm.
Start the engine and lower the loader attachment.
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SECTION 82 - LOADER 9

4. LOADER BUCKET REMOVAL

REMOVAL
Park the machine on flat surface.
Lower the bucket to the ground in dump position (tilt-
ed completely forward).
Stop the engine and remove the ignition switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure in the bucket circuit.
Remove the snap rings and retaining pins and then
drive out the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic sup-
ply lines.
Start the engine.
Operate the attachment controls so as to release the
bucket.
Reverse the machine away from the bucket.

INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then in-
stall the retaining pins and snap rings.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
Shut down the engine and remove the ignition switch
key.
(4x1 bucket) release the pressure in the bucket cir-
cuit.
Install the connecting rod/bucket linkage pins (1) and
then install the retaining pins and snap rings.
(4x1 bucket) remove the plugs and reconnect the hy-
draulic supply lines.
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10 SECTION 82 - LOADER

INSTALLATION LOADER BUCKET WITH MECHANICAL QUICK COUPLER

It is possible to install a mechanical quick coupler (1)
for the loader bucket on the loader arms, using the
standard mounting pins (2).
Make sure the bucket to be installed is in a safe area,
on flat, level ground and with the upper pins in place.
Use the control lever (dumping position) to bring the
quick coupler hooks over the bucket pins (3).
Use the control lever (digging position) to swing the
bucket down onto the lower part of the quick coupler.
Shut down the engine and remove the ignition switch
key.
Install the pins (4) and retaining hardware.

IMPORTANT: make sure the loader bucket is cor-

rectly installed with all its pins and locking rings be-
fore using the loader.
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SECTION 82 - LOADER 11

5. LOADER ARM REMOVAL

Remove loader bucket (see procedure described
previously).
Fully retract bucket cylinders and raise arm until lift
cylinder pivots can be seen above engine guard.
Place a suitable stand under the end of the arm to
take the weight.
Switch off the engine and relieve hydraulic pressure.

Remove the safety rings (2) and the pins and then
drive out the pins (1). Lower the lift cylinders carefully
onto the chassis.

Remove the snap rings (3) and drive out the pins (4).
Lower the arms onto the lift cylinders.

Disconnect and cap the lift cylinder hoses (5) at the

top of the loader arm on each side of the machine
and disconnect the return to dig sensor cable (7) on
the right hand side. If the 4x1 bucket is fitted discon-
nect and cap hose (6) on each side of the loader arm.
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12 SECTION 82 - LOADER

Support loader using a suitable sling.

Remove the safety ring and pins and then pull out the
pin (8).

Remove loader from machine.

INSTALLATION
Installation follows removal procedure in reverse.
 Copyright ©

580 Super R
590 Super R
695 Super R

SECTION 84 - BACKHOE

1. DESCRIPTION AND OPERATION............................................................................................................... 3

2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION .............................................................. 6
3. BACKHOE ATTACHMENT PILOT CONTROL VERSION.......................................................................... 13
4. REMOVAL AND INSTALLATION ............................................................................................................... 15
5. TELESCOPIC DIPPER REVISION............................................................................................................. 25
 Copyright ©

2 SECTION 84 - BACKHOE
 Copyright ©

SECTION 84 - BACKHOE 3

1. DESCRIPTION AND OPERATION

Loader backhoes are available with a centre pivot or
sideshift backhoe assembly.
On centre pivot machines the backhoe pivots on a
fixed central point at the rear of the machine.
Independently operated stabilizers are attached to
the base of the chassis and pivot about an arc to
raise or lower each side of the machine.

On sideshift machines the backhoe is attached to a

carriage hydraulically clamped to the machine frame.
This allows the operator to repositioning the carriage
on the frame and adjust the pivot point on the back-
hoe to suit operating conditions.
The machine is raised using two vertical stabilisers
attached to each side of the machine.

Each stabilizer is independently operated using:

Z levers (1) and (2) on loader backhoe control mod-
els mechanical;

Z control levers (3) and (4) on loader backhoe hy-

draulic pilot control models.
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4 SECTION 84 - BACKHOE

The backhoe is locked in position during transporta-

tion using a hydraulically and mechanically operated
lock (1). The lock is operated by the lever (2) or the
switch (3).

The backhoe on the mechanical control models is

controlled using two main control levers.
Three types of control pattern for 2 lever systems are
available as shown on the following pages. A four le-
ver dealer installed system is also available as a
Dealer installed accessory.

The backhoe on the hydraulic control models is con-

trolled using two rear joysticks (3) and (4).
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SECTION 84 - BACKHOE 5

Machines may be fitted with an optional telescopic

dipper which can be operated simultaneously with
other boom, dipper and bucket movements.

The telescopic dipper on mechanical control models

is controlled using a foot (1) operated pedal at the
rear of the cab.

The telescopic dipper on pilot control modes, is con-

trolled using the two buttons (2) and (3) on the left
joystick.
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6 SECTION 84 - BACKHOE

2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION

Three backhoe attachment control configurations ex-
ist:
Z standard configuration;
Z ISO configuration;
Z cross-pattern configuration.
The operating pattern of the control levers is differ-
ent.

STANDARD CONFIGURATION
Backhoe boom and backhoe attachment swing left-
hand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (A): the backhoe boom lowers.
Position (B): the backhoe boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.

Backhoe dipper and backhoe bucket right-hand

control lever

This lever has five positions:

Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (E): the backhoe dipper extends.
Position (F): the backhoe dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
 Copyright ©

SECTION 84 - BACKHOE 7
 Copyright ©

8 SECTION 84 - BACKHOE

ISO CONFIGURATION

Backhoe dipper and backhoe attachment swing

left-hand control lever

This lever has five positions:

Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.

Backhoe boom and backhoe bucket right-hand

control lever

This lever has five positions:

Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (E): the backhoe boom lowers.
Position (F): the backhoe boom rises.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
 Copyright ©

SECTION 84 - BACKHOE 9
 Copyright ©

10 SECTION 84 - BACKHOE

CROSS-PATTERN CONFIGURATION

Backhoe boom and backhoe attachment swing

left-hand control lever
This lever has five positions:
Position (0): Neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (A): The backhoe boom lowers.
Position (B): The backhoe boom rises.
Position (C): The backhoe attachment swings to the
left.
Position (D): The backhoe attachment swings to the
right.

Backhoe dipper and backhoe bucket right-hand

control lever
This lever has five positions:
Position (0): Neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the attachment remains in the
position where it was when movement stopped.
Position (E): The backhoe dipper extends.
Position (F): The backhoe dipper retracts.
Position (G): The backhoe bucket closes.
Position (H): The backhoe bucket opens.
 Copyright ©

SECTION 84 - BACKHOE 11
 Copyright ©

12 SECTION 84 - BACKHOE

STABILIZER MECHANICAL CONTROLS

Left-hand stabilizer left-hand control lever

This lever has three positions:

Position (0): neutral. This position stops the move-
ment of the left-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral po-
sition (0) and the left-hand stabilizer stops raising or
lowering.
Position (1): the left-hand stabilizer lowers.
Position (2): the left-hand stabilizer rises.

Right-hand stabilizer right-hand control lever

This lever has three positions:

Position (0): neutral. This position stops the move-
ment of the right-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral po-
sition (0) and the right-hand stabilizer stops raising or
lowering.
Position (1): the right-hand stabilizer lowers.
Position (2): the right-hand stabilizer rises.

NOTE: to raise or lower the stabilizers at the same

time, operate the two levers simultaneously.

TELESCOPIC DIPPER MECHANICAL CONTROL

PEDAL
This pedal has three positions:
Position (0): neutral. This position enables the move-
ment of the telescopic dipper to be stopped.

NOTE: the pedal automatically returns to this posi-

tion as soon as it is released.

Position (1): the telescopic dipper extends.

Position (2): the telescopic dipper retracts.
 Copyright ©

SECTION 84 - BACKHOE 13

3. BACKHOE ATTACHMENT PILOT CONTROL VERSION

BACKHOE CONTROLS

Backhoe boom and backhoe attachment swing

left-hand control lever

This control lever has five positions:

Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as re-
leased, it automatically returns to the neutral position
(0) and the attachment remains in the position where
it was when movement stopped.
Position (A): the backhoe boom lowers.
Position (B): the backhoe boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.

Backhoe dipper and backhoe bucket right-hand

control lever

This control lever has five positions:

Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as re-
leased, it automatically returns to the neutral position
(0) and the attachment remains in the position where
it was when movement stopped.
Position (E): the backhoe dipper extends.
Position (F): the backhoe dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.

STABILIZER CONTROLS
These controls are located on the left-hand control
arm and may be used to operate the stabilizers inde-
pendently or simultaneously.

Left-hand stabilizer left-hand control lever

This lever has four positions:

Position (0): neutral. This position stops the move-
ment of the left-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the left-hand
stabilizer stops raising or lowering.
When held in position (1): the left-hand stabilizer low-
ers.
When held in position (2): the left-hand stabilizer ris-
es.
Position (3): see “Auto-Up feature”.
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14 SECTION 84 - BACKHOE

Right-hand stabilizer right-hand control lever

This lever has four positions:

Position (0): neutral. This position stops the move-
ment of the right-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the right-hand
stabilizer stops raising or lowering.
When held in position (1): the right-hand stabilizer
lowers.
When held in position (2): the right-hand stabilizer
rises.
Position (3): see “Auto-Up feature”.

TELESCOPIC DIPPER CONTROLS

Press and hold down the right-hand button (1) to ex-
tend the telescopic dipper. As soon as the button is
released the dipper stops and remains in the position
it occupied when the button was released.
Press and hold down the left-hand button (2) to re-
tract the telescopic dipper. As soon as the button is
released the dipper stops and remains in the position
it occupied when the button was released.
 Copyright ©

SECTION 84 - BACKHOE 15

4. REMOVAL AND INSTALLATION

BACKHOE REMOVE (CENTRE PIVOT VERSION)
Park the machine on a flat surface and position the
backhoe on the ground.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Lower stabilizers sufficiently and however ensure

that the rear tyres are in contact with the ground to
remove the weight from the rear wheels.

IMPORTANT: the rear wheels must remain in con-

tact with the ground.
 Copyright ©

16 SECTION 84 - BACKHOE

Fully retract telescopic dipper, where fitted.

On machines fitted with telescopic dipper install lock-

ing pin in transport hole (1).

Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg.
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Re-check that backhoe elements are fully supported.

Disconnect all hoses that travel through the swing

support reach the backhoe.
 Copyright ©

SECTION 84 - BACKHOE 17

Unscrew and remove the nut (2) to disconnect the

backhoe lock (3).

Remove the snap ring (4), slide out the pin (5) and by
means of an hammer remove the pin (6) of swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move snap ring (7).
Slide out the pin (8) and by means of an hammer re-
move the lower pin (9) from swing support.

Unscrew the screw (10).

Remove the upper pin (11) of swing support.

Now it is possible to remove from the backhoe the

backhoe assembly.
 Copyright ©

18 SECTION 84 - BACKHOE

BACKHOE REMOVE (SIDESHIFT VERSION)

Park the machine on a flat surface and position the
backhoe on the ground.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Lower stabilizers sufficiently and however ensure

that the rear tyres are in contact with the ground to
remove the weight from the rear wheels.

IMPORTANT: the rear wheels must remain in con-

tact with the ground.

Fully retract telescopic dipper, where fitted.

 Copyright ©

SECTION 84 - BACKHOE 19

On machines fitted with telescopic dipper install lock-

ing pin in transport hole (1).

Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg.
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Re-check that backhoe elements are fully supported.

F30332

Disconnect all hoses that travel through the swing

support reach the backhoe.

Unscrew and remove the nut (2) to disconnect the

backhoe lock (3).
 Copyright ©

20 SECTION 84 - BACKHOE

Remove the snap ring (4), slide out the pin (5) and by
means of an hammer remove the pin (6) of swing cyl-
inder.
Repeat the operation with both swing cylinders. Re-
move snap ring (7).
Slide out the pin (8) and by means of an hammer re-
move the lower pin (9) from swing support.

Unscrew the screw (10).

Remove the upper pin (11) of swing support.

Now it is possible to remove from the backhoe the

backhoe assembly.
 Copyright ©

SECTION 84 - BACKHOE 21

BACKHOE BUCKET REMOVAL

Park the machine on a flat surface.
Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
Stop the engine and remove the starter switch key.

Remove the safety split pin (1).

Slide out the pin (2).
Start the engine.
Move the arm so that the hook (3) can get relased
from the bucket pin (4).
Remove the backhoe bucket.
 Copyright ©

22 SECTION 84 - BACKHOE

DIPPER REMOVE
Park the machine on a level, firm surface and posi-
tion the backhoe on the ground.

SWARNING
Always support the structural members so that they
will be stable and safe to work around.

Lower stabilizers sufficiently to remove the weight

from the rear wheels.

IMPORTANT: the rear wheels must remain in con-

tact with the ground.

Install locking pin in transport hole (1) [on machines

fitted with telescopic dipper].
 Copyright ©

SECTION 84 - BACKHOE 23

Lower the backhoe to the ground and support using

a suitable stand.
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.

Disconnect hoses to dipper cylinders.

Telescopic dipper hoses.

Standard dipper hose.

Support dipper cylinder, unscrew and remove the

screw (2), slide out the pin (3).
Lower cylinder onto boom. Use suitable cylinder sup-
ports to ensure weight of cylinder does not damage
hydraulic tubes attached to dipper.
 Copyright ©

24 SECTION 84 - BACKHOE

Support dipper using suitable hoist. Unscrew and re-

move the screw (4), slide out the pin (5) and carefully
lower dipper to the ground.
 Copyright ©

SECTION 84 - BACKHOE 25

5. TELESCOPIC DIPPER REVISION

INSPECTION OF GUIDE PADS
Park the machine on level ground and retract the tel-
escopic dipper.
Position the dipper on a suitable stand with the buck-
et raised from the ground.
Clean the area around the pads.

Inspect each upper guide pad and if the chamfered

edge (1) on the corner of the pads is no longer visible
the pads have worn beyond their limit and must be
replaced.
If pads do not require replacement visually check if
the gap between the inner part of the dipper and up-
per guide pad is greater than 1.5 mm.
If the gap is greater than 1.5 mm the guide pads must
be adjusted.
 Copyright ©

26 SECTION 84 - BACKHOE

ADJUSTMENT OF GUIDE PADS

Position the dipper in the vertical position.
Count the number of shims behind the adjusting
screws on the left and right hand sides of the dipper
to determine which side has the most shims.
Remove one shim from behind an adjusting screw
on the side of the dipper which contains the most
shims.
Refit the screw and tighten to a torque of 350 - 400
Nm. DO Not over torque the screw.
Repeat the procedure for the remaining three screws
on the same side of the dipper.
Recheck the gap.
If the gap remains greater than 1.5 mm remove a
shim from behind each of the adjusting screws on the
opposite side of the dipper.
After performing an adjustment apply a coat of Dry
Moly-coat grease to the slide rails of the dipper.

NOTE: when all shims have been removed the guide

pads must be replaced.

REPLACEMENT OF GUIDE PADS

To replace the guide pads it is necessary to separate
the inner and outer parts of the telescopic dipper us-
ing either of the following procedures which are de-
pendent on workshop facilities.

Procedure No. 1

Park the machine on level ground and lower loader

bucket.
Lower stabilizers sufficiently to remove the weight
from the rear wheels.

IMPORTANT: the rear wheels must remain in con-

tact with the ground.

Position dipper on a suitable stand.

Attach hoist to inner part of dipper.
Disconnect hose connections to bucket and tele-
scopic dipper cylinders.
Remove telescopic dipper cylinder pin (1) and sepa-
rate inner and outer parts of telescopic dipper.
 Copyright ©

SECTION 84 - BACKHOE 27

Unscrew and remove the screws (2).

Remove the guide pads (3). Install new pads and ap-
ply thread sealant part No. 82995773 to the retaining
screws. Tighten to a torque of 29 - 31 Nm. Do not
over tighten or damage to the threaded inserts may
occur.

Re-assemble inner and outer parts of telescopic dip-

per.
Place 5 shims beneath the heads of each adjusting
screw.
Adjust guide pads as described previously.

Procedure No. 2

This procedure requires the use of a loading dock or

service pit.
Park the machine with backhoe positioned over load-
ing dock or service pit.
Place the loader bucket on the ground and lower sta-
bilizers sufficiently to remove the weight from the
rear wheels.
Attach suitable hoist to top of inner section of dipper
and position boom so that dipper is hanging vertical-
ly.
Disconnect hose connections at bucket and tele-
scopic dipper cylinders.
Remove telescopic dipper cylinder retaining pin.
Slowly lower hoist allowing inner and outer parts of
telescopic dipper to separate.

Unscrew and remove the screws (2).

Remove the guide pads (3). Install new guide pads
and apply thread sealant to the retaining screws.
Tighten to a torque of 29 - 31 Nm. Do not over tighten
or damage to the threaded inserts may occur.
Position new lower guide pads in the outer part of the
telescopic dipper.

Re-assemble inner and outer parts of telescopic dip-

per.
Place 5 shims beneath the heads of each adjusting
screw.
Adjust guide pads as described previously.
 Copyright ©

28 SECTION 84 - BACKHOE

NOTE: